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Full text of "Yamaha YZ 450 F 2003 Manual de taller"



OWNER'S SERVICE MANU 




Z450FR 



5TA-28T98-1 



A WARNING 



The engine exhaust from this product 
contains chemicals known to the 
State of California to cause cancer, birth 
defects or other reproductive harm. 



YAMAHA 



LIT-CALIF-65-01 



EC010000 

YZ450FR 

OWNER'S SERVICE MANUAL 

©2002 by Yamaha Motor Corporation, U.S.A. 

1st Edition, June 2002 

All rights reserved. Any reprinting or 

unauthorized use without the written 

permission of Yamaha Motor Corporation 

U.S.A. is expressly prohibited. 

Printed in Japan 

P/N.LIT-1 1626-1 6-38 



EC020000 

INTRODUCTION 



Congratulations on your purchase of a 
Yamaha YZ series. This model is the culmina- 
tion of Yamaha's vast experience in the pro- 
duction of pacesetting racing machines. It 
represents the highest grade of craftsmanship 
and reliability that have made Yamaha a 
leader. 

This manual explains operation, inspection, 
basic maintenance and tuning of your 
machine. If you have any questions about this 
manual or your machine, please contact your 
Yamaha dealer. 

NOTE: 

As improvements are made on this model, 
some data in this manual may become out- 
dated. If you have any questions, please con- 
sult your Yamaha dealer. 



A WARNING 



PLEASE READ THIS MANUAL CAREFULLY 
AND COMPLETELY BEFORE OPERATING 
THIS MACHINE. DO NOT ATTEMPT TO 
OPERATE THIS MACHINE UNTIL YOU 
HAVE ATTAINED A SATISFACTORY 
KNOWLEDGE OF ITS CONTROLS AND 
OPERATING FEATURES AND UNTIL YOU 
HAVE BEEN TRAINED IN SAFE AND 
PROPER RIDING TECHNIQUES. REGULAR 
INSPECTIONS AND CAREFUL MAINTE- 
NANCE, ALONG WITH GOOD RIDING 
SKILLS, WILL ENSURE THAT YOU SAFETY 
ENJOY THE CAPABILITIES AND THE RELI- 
ABILITY OF THIS MACHINE. 



EC030002 

YAMAHA MOTOR CORPORATION, U.S.A. 
YZ/WR MOTORCYCLE LIMITED WARRANTY 



Yamaha Motor Corporation, U.S.A. hereby war- 
rants to the original retail purchaser that the fol- 
lowing components equipped on new Yamaha YZ 
or WR motorcycles purchased from an authorized 
Yamaha motorcycle dealer in the continental 
United States will be free from defects in material 
and workmanship for the period of time stated 
herein, subject to certain stated limitations. YZ or 
WR components included under this warranty are 
the engine, frame, swingarm, and monoshock. It is 
understood that the balance of the YZ or WR com- 
ponents are not covered by any warranty, 
expressed or implied. The balance of the compo- 
nents equipped on the unit are sold on an "as is" 
basis. This warranty applies to the original pur- 
chaser only and is not transferable. 

THE PERIOD OF WARRANTY for the above-listed 
Yamaha YZ or WR components as originally 
installed on the unit shall be thirty (30) days from 
the date of purchase. 

MODELS EXCLUDED FROM WARRANTY include 
those used for non-Yamaha-authorized renting, 
leasing, or other commercial purposes. 

DURING THE PERIOD OF WARRANTY any autho- 
rized Yamaha motorcycle dealer will, free of 
charge, repair or replace, at Yamaha's option, any 
part adjudged defective by Yamaha due to faulty 
workmanship or material from the factory. Parts 
used in warranty repairs will be warranted for the 
balance of the product's warranty period. All parts 
replaced under warranty become property of 
Yamaha Motor Corporation U.S.A. 

GENERAL EXCLUSIONS from this warranty shall 
include any failures caused by: 



a. Installation of parts or accessories that are not 
qualitatively equivalent to genuine Yamaha 
parts. 

b. Abnormal strain, neglect, or abuse. 

c. Accident or collision damage. 

d. Modification to original parts. 

e. Lack of proper maintenance. 

f. Damage due to improper transportation. 

SPECIFIC EXCLUSIONS from this warranty shall 
include parts replaced due to normal wear or rou- 
tine maintenance. 

THE CUSTOMER'S RESPONSIBILITY under this 
warranty shall be to: 

1. Operate and maintain the YZ or WR as speci- 
fied in the appropriate Owner's Service Man- 
ual, and 

2. Give notice to an authorized Yamaha motorcy- 
cle dealer of any and all apparent defects 
within ten (10) days after discovery, and make 
the machine available at that time for inspec- 
tion and repairs at such dealer's place of busi- 
ness. 

YAMAHA MOTOR CORPORATION, U.S.A. MAKES 
NO OTHER WARRANTY OF ANY KIND, 
EXPRESSED OR IMPLIED. ALL IMPLIED WARRAN- 
TIES OF MERCHANTABILITY AND FITNESS FOR A 
PARTICULAR PURPOSE WHICH EXCEED THE 
OBLIGATIONS AND TIME LIMITS STATED IN THIS 
WARRANTY ARE HEREBY DISCLAIMED BY 
YAMAHA MOTOR CORPORATION U.S.A. AND 
EXCLUDED FROM THIS WARRANTY. 

SOME STATES DO NOT ALLOW LIMITATIONS ON 
HOW LONG AN IMPLIED WARRANTY LASTS, SO 
THE ABOVE 



LIMITATION MAY NOT APPLY TO YOU. ALSO 
EXCLUDED FROM THIS WARRANTY ARE ANY 
INCIDENTAL OR CONSEQUENTIAL DAMAGES 
INCLUDING LOSS OF USE. SOME STATES DO 
NOT ALLOW THE EXCLUSION OR LIMITATION OF 
INCIDENTAL OR CONSEQUENTIAL DAMAGES, SO 
THE ABOVE EXCLUSION MAY NOT APPLY TO 
YOU. 

THIS WARRANTY GIVES YOU SPECIFIC LEGAL 
RIGHTS, AND YOU MAY ALSO HAVE OTHER 
RIGHTS WHICH VARY FROM STATE TO STATE. 

YAMAHA MOTOR CORPORATION, U.S.A. 

Post Office Box 6555 

Cypress, California 90630 



WARRANTY QUESTIONS AND ANSWERS 

Q. What costs are my responsibility during the warranty period? 

A. The customer's responsibility includes all costs of normal maintenance services, non-war- 
ranty repairs, accident and collision damage, and oil, oil filters, air filters, spark plugs, and 
brake shoes or pads. 

Q. What are some examples of "abnormal" strain, neglect, or abuse? 

A. These terms are general and overlap each other in areas. Specific examples include: Run- 
ning the machine without oil; operating the machine with a broken or damaged part 
which causes another part to fail, damage or failure due to improper or, careless transpor- 
tation and or tie down; and so on. If you have any specific questions on operation or 
maintenance, please contact your dealer for advice. 

Q. Does the warranty cover incidental costs such as towing or transportation due to a fail- 
ure? 
A. No. The warranty is limited to repair of the machine itself. 

Q. May I perform any or all of the recommended maintenance shown in the Owner's Service 
Manual instead of having the dealer do them? 

A. Yes, if you are a qualified mechanic and follow the procedures specified in the Owner's 
Service Manual. We do recommend, however, that items requiring special tools or equip- 
ment be done by a Yamaha motorcycle dealer. 

Q. Will the warranty be void or canceled if I do not operate or maintain my new YZ or WR 
exactly as specified in the Owner's Service Manual? 

A. No. The warranty on a new motorcycle cannot be "voided" or "cancelled." However, if a 
particular failure is caused by operation or maintenance other than as shown in the 
Owner's Service Manual, that failure may not be covered under warranty. 

Q. What responsibility does my dealer have under this warranty? 
A. Each Yamaha motorcycle dealer is expected to: 

1 . Completely set up every new machine before sale. 

2. Explain the operation, maintenance, and warranty requirements to your satisfaction 
at the time of sale, and upon your request at any later date. 

In addition, each Yamaha motorcycle dealer is held responsible for his setup, service 

and warranty repair work. 
Q. Does the warranty on the engine include the carburetor, air filter, air box, and exhaust 

pipe? 
A. No. The warranty covers only the engine components. 



CUSTOMER SERVICE 

If your machine requires warranty service, you must take it to any authorized 
Yamaha motorcycle dealer within the continental United States. Be sure to bring 
your warranty registration identification or other valid proof of the original date 
of purchase. If a question or problem arises regarding warranty, first contact the 
owner of the dealer-ship. Since all warranty matters are handled at the dealer 
level, this person is in the best position to help you. If you are still not satisfied 
and require additional assistance, please write: 

YAMAHA MOTOR CORPORATION U.S.A. 

CUSTOMER RELATIONS DEPARTMENT 

P.O. Box 6555 

Cypress, California 90630 

When contacting Yamaha Motor Corporation, U.S.A. don't forget to include any 
important information such as names, addresses, model, V.I.N, (frame number), 
dates, and receipts. 

CHANGE OF ADDRESS 

The federal government requires each manufacturer of a motor vehicle to main- 
tain a complete, up-to-date list of all first purchasers against the possibility of a 
safety-related defect and recall. This list is compiled from the purchase registra- 
tions sent to Yamaha Motor Corporation, U.S.A. by the selling dealer at the time 
of your purchase. 

If you should move after you have purchased your new motorcycle, please 
advise us of your new address by sending a postcard listing your motorcycle 
model name, V.I.N, (frame number), dealer number (or deale's name) as it is 
shown on your warranty identification, your name and new mailing address. 
Mail to: 

YAMAHA MOTOR CORPORATION, U.S.A. 

WARRANTY DEPARTMENT 

P.O.Box 6555 

Cypress, California 90630 

This will ensure that Yamaha Motor Corporation, U.S.A. has an up-to-date regis- 
tration record in accordance with federal law. 



IMPORTANT NOTICE 

THIS MACHINE IS DESIGNED STRICTLY 
FOR COMPETITION USE, ONLY ON A 
CLOSED COURSE. It is illegal for this 
machine to be operated on any public street, 
road, or highway. Off-road use on public lands 
may also be illegal. Please check local regula- 
tions before riding. 



ASAFETY INFORMATION 



1. THIS MACHINE IS TO BE OPERATED 
BY AN EXPERIENCED RIDER ONLY. 
Do not attempt to operate this 
machine at maximum power until you 
are totally familiar with its character- 
istics. 

2. THIS MACHINE IS DESIGNED TO BE 
RIDDEN BY THE OPERATOR ONLY. 
Do not carry passengers on this 
machine. 

3. ALWAYS WEAR PROTECTIVE 
APPAREL. 

When operating this machine, always 
wear an approved helmet with gog- 
gles or a face shield. Also wear heavy 
boots, gloves, and protective cloth- 
ing. Always wear proper fitting cloth- 
ing that will not be caught in any of 
the moving parts or controls of the 
machine. 

4. ALWAYS MAINTAIN YOUR MACHINE 
IN PROPER WORKING ORDER. 

For safety and reliability, the machine 
must be properly maintained. Always 
perform the pre-operation checks 
indicated in this manual. Correcting a 
mechanical problem before you ride 
may prevent an accident. 

5. GASOLINE IS HIGHLY FLAMMABLE. 
Always turn off the engine while refu- 
eling. Take care to not spill any gaso- 
line on the engine or exhaust system. 
Never refuel in the vicinity of an open 
flame, or while smoking. 



6. GASOLINE CAN CAUSE INJURY. 

If you should swallow some gasoline, 
inhale excess gasoline vapors, or 
allow any gasoline to get into your 
eyes, contact a doctor immediately. If 
any gasoline spills onto your skin or 
clothing, immediately wash skin areas 
with soap and water, and change your 
clothes. 

7. ONLY OPERATE THE MACHINE IN AN 
AREA WITH ADEQUATE VENTILA- 
TION. 

Never start the engine or let it run for 
any length of time in an enclosed area. 
Exhaust fumes are poisonous. These 
fumes contain carbon monoxide, 
which by itself is odorless and color- 
less. Carbon monoxide is a dangerous 
gas which can cause unconscious- 
ness or can be lethal. 

8. PARK THE MACHINE CAREFULLY; 
TURN OFF THE ENGINE. 

Always turn off the engine if you are 
going to leave the machine. Do not 
park the machine on a slope or soft 
ground as it may fall over. 

9. THE ENGINE, EXHAUST PIPE, MUF- 
FLER, AND OIL TANK WILL BE VERY 
HOT AFTER THE ENGINE HAS BEEN 
RUN. 

Be careful not to touch them or to 
allow any clothing item to contact 
them during inspection or repair. 

10. PROPERLY SECURE THE MACHINE 
BEFORE TRANSPORTING IT. 

When transporting the machine in 
another vehicle, always be sure it is 
properly secured and in an upright 
position and that the fuel cock is in 
the "OFF" position. Otherwise, fuel 
may leak out of the carburetor or fuel 
tank. 



EC050000 

TO THE NEW OWNER 



This manual will provide you with a good basic 
understanding of features, operation, and 
basic maintenance and inspection items of this 
machine. Please read this manual carefully 
and completely before operating your new 
machine. If you have any questions regarding 
the operation or maintenance of your machine, 
please consult your Yamaha dealer. 

NOTE: 

This manual should be considered a perma- 
nent part of this machine and should remain 
with it even if the machine is subsequently 
sold. 



EC060000 

NOTICE 



Some data in this manual may become out- 
dated due to improvements made to this 
model in the future. If there is any question 
you have regarding this manual or your 
machine, please consult your Yamaha 
dealer. 

EC070001 

F.I.M. MACHINE WEIGHTS: 



Weights of machines without fuel 

The minimum weights for motocross 
machines are: 

for the class 125 cc minimum 

88 kg (194 lb) 

for the class 250 cc minimum 

98 kg (216 lb) 

for the class 500 cc minimum 

102 kg (225 lb) 
In modifying your machine (e.g., for weight 
reduction), take note of the above limits of 
weight. 



EC080000 



HOW TO USE 
THIS MANUAL 



EC081000 

PARTICULARLY IMPORTANT 
INFORMATION 



The Safety Alert Symbol means ATTENTION! 
BECOME ALERT! YOUR SAFETY IS 
INVOLVED! 



A WARNING 



Failure to follow WARNING instructions could 
result in severe injury or death to the machine 
operator, a bystander, or a person inspecting 
or repairing the machine. 



: §#l H:g 

A CAUTION indicates special precautions that 

must be taken to avoid damage to the 

machine. 

NOTE: 

A NOTE provides key information to make pro- 
cedures easier or clearer. 




EC082000 

FINDING THE REQUIRED PAGE 

1 . This manual consists of seven chapters; 
"General Information", "Specifications", 
"Regular inspection and adjustments", 
"Engine", "Chassis", "Electrical" and 
"Tuning". 

2. The table of contents is at the beginning 
of the manual. Look over the general lay- 
out of the book before finding then 
required chapter and item. 

Bend the book at its edge, as shown, to 
find the required fore edge symbol mark 
and go to a page for required item and 
description. 



EC083000 

MANUAL FORMAT 

All of the procedures in this manual are organized in a sequential, step-by-step format. The informa- 
tion has been complied to provide the mechanic with an easy to read, handy reference that contains 
comprehensive explanations of all disassembly, repair, assembly, and inspection operations. 
In this revised format, the condition of a faulty component will precede an arrow symbol and the 
course of action required will follow the symbol, e.g., 
• Bearings 
Pitting/damage -> Replace. 

EC084002 

HOW TO READ DESCRIPTIONS 

To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each 
removal and disassembly section. 

1 . An easy-to-see exploded diagram © is provided for removal and disassembly jobs. 

2. Numbers ® are given in the order of the jobs in the exploded diagram. A number that is 
enclosed by a circle indicates a disassembly step. 

3. An explanation of jobs and notes is presented in an easy-to-read way by the use of symbol 
marks ©. The meanings of the symbol marks are given on the next page. 

4. A job instruction chart accompanies the exploded diagram, providing the order of jobs, 
names of parts, notes in jobs, etc. 

5. Extent of removal (§) is provided in the job instruction chart to save the trouble of an unneces- 
sary removal job. 

6. For jobs requiring more information, the step-by-step format supplements ® are given in addi- 
tion to the exploded diagram and job instruction chart. 




CLUTCH ENG % 








Extent of removal 






/ 


JQ Push rod and push lever removal 
© Friction plate and clutch plate removal 


© Push pod 1 disassembly 
© Clutch housing removal 




Extent of rem 


.at/ 


Order 


Part name 


Q'ty 


Remarks 










CLUTCH REMOVAL 









Preparajierfrfor r 


moval 




Drain the engine oil. 




Refer to "ENGINE OIL REPLACEMENT" 
section in the CHAPTER 3. 


(§Y 








Brake pedal 
Clutch cable 




Refer to "ENGINE REMOVAL" section. 
Disconnect at engine side. 








I 






1 


Clutch cover 


1 






\ 










2 


Gasket 


1 






Y 


) 


i! 


Q 


) 


3 
4 
5 
6 


Dowel pin 
Clutch spring 
Pressure plate 
Push rod 1 


2 
6 

1 












7 


Pl'ail'washer 


1 






6 






9 
10 


Bearing 
Ball 
Push rod 2 


; 







REMOVAL POINTS 

Clutch boss 

1. Remove: 

• Nut© 

• Lock washer © 

• Clutch boss © 

NOTE: 

Straighten the lock washer tab and use the 
clutch holding tool © to hold the clutch boss. 



kD 



^ 



INSPECTION 

Clutch housing and boss 

1. Inspect: 

• Clutch housing © 
Cracks/wear/damage -> Replace. 

• Clutch boss © 
Scoring/wear/damage -> Replace. 



Primary driven gear 

1. Check: 

• Circumferential play 

Free play exists -> Replace. 

• Gear teeth ® 
Wear/damage -> Replace. 



Clutch spring 

1. Measure: 

• Clutch spring free length © 
Out of specification -> Replace springs 
as a set. 



<£ 


Clutch spring free length: 


Standard 


<Limit> 


50 mm (1.97 in) 


49 mm (1.93 in) 



© 


© 


GEN 
INFO 


(?fr§ 


SPEC 


a— 


© 


© 


INSP 
ADJ 


<& 


ENG 


.» 


© 


© 


CHAS 


gN> 


ELEC 


- + 


© 


© 


TUN 




HA 


&G 




® 


p. 




© 


'■O 




© 


— 




© 


X 




© 


X 




© 


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© © 

1 1 


© © 


© © 






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ILLUSTRATED SYMBOLS 
(Refer to the illustration) 

Illustrated symbols © to ® are designed as 
thumb tabs to indicate the chapter's number 
and content. 

© General information 

© Specifications 

© Regular inspection and adjustments 

© Engine 

© Chassis 

© Electrical 

©Tuning 

Illustrated symbols © to © are used to identify 
the specifications appearing in the text. 

© With engine mounted 

© Special tool 

© Filling fluid 

© Lubricant 

© Tightening 

© Specified value, Service limit 

© Resistance (Q), Voltage (V), Electric current (A) 



Illustrated symbols © to ® in the exploded 
diagrams indicate grade of lubricant and loca- 
tion of lubrication point. 

© Apply engine oil 

© Apply molybdenum disulfide oil 

© Apply lightweight lithium-soap base grease 

© Apply molybdenum disulfide grease 



Illustrated symbols ® to ® in the exploded 
diagrams indicate where to apply a locking 
agent and where to install new parts. 

© Apply locking agent (LOCTITE®) 
© Use new one 



MEMO 



EC090000 



INDEX 



GENERAL 
INFORMATION 


§fc§ 


gen n 

INFO ■■ 




SPECIFICATIONS 


a— 


SPEC^| 




REGULAR 
INSPECTION AND 
ADJUSTMENTS 


<& 


INSP CI 
ADJ N 




ENGINE 


%m 


ENG Wa\ 




CHASSIS 


<jfcs> 


CHASfcJ 




ELECTRICAL 


- + 


ELEC[=j 




TUNING 


© 


TUN WA 



ECOAOOOO 

CONTENTS 



CHAPTER 1 
GENERAL INFORMATION 



DESCRIPTION 1-1 

MACHINE IDENTIFICATION 1-2 

IMPORTANT INFORMATION 1-3 

CHECKING OF CONNECTION 1-6 

SPECIAL TOOLS 1-7 

CONTROL FUNCTIONS 1-10 

FUEL 1-13 

STARTING AND BREAK-IN 1-14 

TORQUE-CHECK POINTS 1-18 

CLEANING AND STORAGE 1-19 



CHAPTER 2 
SPECIFICATIONS 



GENERAL SPECIFICATIONS 2-1 

MAINTENANCE SPECIFICATIONS 2-4 

GENERAL TORQUE 

SPECIFICATIONS 2-18 

DEFINITION OF UNITS 2-18 

LUBRICATION DIAGRAMS 2-19 

CABLE ROUTING DIAGRAM 2-21 



CHAPTER 3 

REGULAR INSPECTION AND 

ADJUSTMENTS 



MAINTENANCE INTERVALS 3-1 

PRE-OPERATION INSPECTION 

AND MAINTENANCE 3-4 

ENGINE 3-5 

CHASSIS 3-24 

ELECTRICAL 3-45 



CHAPTER 4 
ENGINE 



SEAT, FUEL TANK 

AND SIDE COVERS 4-1 

EXHAUST PIPE AND SILENCER 4-3 

RADIATOR 4-5 

CARBURETOR 4-8 

CAMSHAFTS 4-21 

CYLINDER HEAD 4-29 

VALVES AND VALVE SPRINGS 4-33 

CYLINDER AND PISTON 4-42 

CLUTCH 4-48 

OIL FILTER, WATER PUMP 

AND CRANKCASE COVER (RIGHT) 4-55 

BALANCER 4-62 

OIL PUMP 4-65 

KICK AXLE AND SHIFT SHAFT 4-69 

CDI MAGNETO 4-76 

ENGINE REMOVAL 4-80 

CRANKCASE AND CRANKSHAFT 4-85 

TRANSMISSION, SHIFT CAM 

AND SHIFT FORK 4-94 



CHAPTER 5 
CHASSIS 



FRONT WHEEL AND REAR WHEEL 5-1 

FRONT BRAKE AND REAR BRAKE 5-10 

FRONT FORK 5-26 

HANDLEBAR 5-39 

STEERING 5-45 

SWINGARM 5-50 

REAR SHOCK ABSORBER 5-58 



CHAPTER 6 
ELECTRICAL 



ELECTRICAL COMPONENTS 

AND WIRING DIAGRAM 6-1 

MAP-CONTROLLED CDI UNIT 6-2 

IGNITION SYSTEM 6-3 

TPS (THROTTLE POSITION SENSOR) 
SYSTEM 6-7 



CHAPTER 7 
TUNING 



ENGINE 7-1 

CHASSIS 7-10 



DESCRIPTION 




EC1 00000 

GENERAL INFORMATION 

EC1 10000 

DESCRIPTION 

© Clutch lever 

© Hot starter lever 

© Front brake lever 

© Throttle grip 

© Radiator cap 

© Fuel tank cap 

©"ENGINE STOP" button 

© Kick starter 

© Fuel tank 

© Radiator 

© Coolant drain bolt 

© Rear brake pedal 

® Valve joint 

© Fuel cock 

© Cold starter knob 

© Drive chain 

@ Air cleaner 

© Shift pedal 

® Oil dipstick 

© Front fork 



NOTE: 

• The machine you have purchased may differ 
slightly from those shown in the following. 

• Designs and specifications are subject to 
change without notice. 







1 -1 



MACHINE IDENTIFICATION 





EC1 20001 

MACHINE IDENTIFICATION 

There are two significant reasons for knowing 
the serial number of your machine: 

1. When ordering parts, you can give the 
number to your Yamaha dealer for posi- 
tive identification of the model you own. 

2. If your machine is stolen, the authorities 
will need the number to search for and 
identify your machine. 

EC121001 

VEHICLE IDENTIFICATION NUMBER 

The vehicle identification number © is 
stamped on the right of the steering head pipe. 



EC1 23001 

ENGINE SERIAL NUMBER 

The engine serial number © is stamped into 
the elevated part of the right-side of the 
engine. 



EC1 24000 

MODEL LABEL 

The model label © is affixed to the frame 
under the rider's seat. This information will be 
needed to order spare parts. 



1 -2 



IMPORTANT INFORMATION 






EC1 30000 

IMPORTANT INFORMATION 

EC131010 

PREPARATION FOR REMOVAL AND 
DISASSEMBLY 

1. Remove all dirt, mud, dust, and foreign 
material before removal and disassem- 
bly. 

When washing the machine with high 
pressured water, cover the parts as fol- 
lows. 

• Silencer exhaust port 

• Side cover air intake port 

• Water pump housing hole at the bottom 

• Drain hole on the cylinder head (right 
side) 




Use proper tools and cleaning equip- 
ment. Refer to "SPECIAL TOOLS" sec- 
tion. 




3. When disassembling the machine, keep 
mated parts together. They include 
gears, cylinders, pistons, and other 
mated parts that have been "mated" 
through normal wear. Mated parts must 
be reused as an assembly or replaced. 




4. During the machine disassembly, clean 
all parts and place them in trays in the 
order of disassembly. This will speed up 
assembly time and help assure that all 
parts are correctly reinstalled. 

5. Keep away from fire. 



1 -3 



IMPORTANT INFORMATION 




EC1 32000 

ALL REPLACEMENT PARTS 

1. We recommend to use Yamaha genuine 
parts for all replacements. Use oil and/or 
grease recommended by Yamaha for 
assembly and adjustment. 



EC1 33000 

GASKETS, OIL SEALS AND O-RINGS 

1. All gaskets, oil seals, and O-rings should 
be replaced when an engine is over- 
hauled. All gasket surfaces, oil seal lips, 
and O-rings must be cleaned. 

2. Properly oil all mating parts and bearings 
during reassembly. Apply grease to the 
oil seal lips. 






EC1 34000 

LOCK WASHERS/PLATES AND COTTER 
PINS 

1 . All lock washers/plates © and cotter pins 
must be replaced when they are 
removed. Lock tab(s) should be bent 
along the bolt or nut flat(s) after the bolt 
or nut has been properly tightened. 



EC1 35001 

BEARINGS AND OIL SEALS 

1 . Install the bearing(s) © and oil seal(s) © 
with their manufacturer's marks or num- 
bers facing outward. (In other words, the 
stamped letters must be on the side 
exposed to view.) When installing oil 
seal(s), apply a light coating of light- 
weight lithium base grease to the seal 
lip(s). Oil the bearings liberally when 
installing. 

CAUTION; 

Do not use compressed air to spin the 
bearings dry. This causes damage to the 
bearing surfaces. 



1 -4 



IMPORTANT INFORMATION 





EC1 36000 

CIRCLIPS 

1. All circlips should be inspected carefully 
before reassembly. Always replace pis- 
ton pin clips after one use. Replace dis- 
torted circlips. When installing a circlip 
©, make sure that the sharp-edged cor- 
ner (2) is positioned opposite to the thrust 
(5) it receives. See the sectional view. 
© Shaft 



1 -5 



CHECKING OF CONNECTION 





EC1C0001 

CHECKING OF CONNECTION 

Dealing with stains, rust, moisture, etc. on the 
connector. 

1 . Disconnect: 
• Connector 

2. Dry each terminal with an air blower. 



3. Connect and disconnect the connector 
two or three times. 

4. Pull the lead to check that it will not come 
off. 

5. If the terminal comes off, bend up the pin 
© and reinsert the terminal into the con- 
nector. 









T 




;< 


i 


>; 


tt ' ^^*^» ' — ' 




18020103 















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^r 






j( 


i 


>; 














18020 


107 



6. Connect: 

• Connector 

NOTE: 

The two connectors "click" together. 

7. Check for continuity with a tester. 

NOTE: 

• If there in no continuity, clean the terminals. 

• Be sure to perform the steps 1 to 7 listed 
above when checking the wireharness. 

• For a field remedy, use a contact revitalizer 
available on the market. 

• Use the tester on the connector as shown. 



1 -6 



SPECIAL TOOLS 




EC1 40001 

SPECIAL TOOLS 

The proper special tools are necessary for complete and accurate tune-up and assembly. Using the 
correct special tool will help prevent damage caused by the use of improper tools or improvised 
techniques. The shape and part number used for the special tool differ by country, so two types are 
provided. Refer to the list provided to avoid errors when placing an order. 

NOTE: 

• For U.S.A. and Canada, use part number starting with "YM-" , "YU-" or "ACC-". 

• For others, use part number starting with "90890-". 



Part number 



Tool name/How to use 



Illustration 



YU-1135-A, 90890-01135 



Crankcase separating tool 



These tool is used to remove the crankshaft from 
either case. 



YU-1135-A 




90890-01135 




YU-1 235, 90890-01235 



Rotor holding tool 



This tool is used when loosening or tightening the fly- 
wheel magneto securing nut. 



YU-1 235 




90890-01235 




YU-3097, 90890-01252 
YU-1 256 



Dial gauge and stand 
Stand 



These tools are used to check each part for runout or 
bend. 



YU-3097 
YU-1 256 



90890-01252 





YU-90050, 90890-01274 
YU-90050, 90890-01275 
YU-91 044, 90890-04081 
YU-90063, 90890-01278 



Crankshaft installing tool 

Crankshaft installing pot 

Crankshaft installing bolt 

Spacer (crankshaft installer) 

Adapter (M 12) 

These tools are used to install the crankshaft. 



YU-90050 
YU-90063 
YU-91 044 




90890-01274 
90890-01275 
90890-01278 
90890-04081 




YU-1 304, 90890-01304 



Piston pin puller 



This tool is used to remove the piston pin. 



YU-1 304 




90890-01304 




YU-24460-01, 90890-01325 
YU-33984, 90890-01352 



Radiator cap tester 
Adapter 



These tools are used for checking the cooling sys- 
tem. 



YU-24460-01 
YU-33984 



90890-01325 
90890-01352 






YM-1 189, 90890-01189 



Flywheel puller 



This tool is used to remove the flywheel magneto. 



YM-1 189 



90890-01189 





1 -7 



SPECIAL TOOLS 




Part number 



Tool name/How to use 



Illustration 



YU-33975, 90890-01403 



Ring nut wrench 



This tool is used when tighten the steering ring nut to 
specification. 



YU-33975 




90890-01403 




YM-1 423, 90890-01423 



Damper rod holder 



Use this tool to remove and install the damper rod. 



YM-1 423 




90890-01423 




YM-01 442, 90890-01442 



Fork seal driver 



This tool is used when install the fork oil seal. 



YM-01 442 



90890-01442 





YU-3112-C, 90890-03112 



Yamaha pocket tester 



Use this tool to inspect the coil resistance, output 
voltage and amperage. 



YU-3112-C 



/ 




90890-03112 



/ 




YU-8036-B 



90890-03113 



Inductive tachometer 
Engine tachometer 



This tool is needed for observing engine rpm. 



YU-8036-B 




90890-03113 




YM-33277-A, 90890-03141 



Timing light 



This tool is necessary for checking ignition timing. 



YM-33277-A 



90890-03141 





YM-401 9, 90890-04019 



Valve spring compressor 



This tool is needed to remove and install the valve 
assemblies. 



YM-401 9 



90890-04019 





YM-91 042, 90890-04086 



Clutch holding tool 



This tool is used to hold the clutch when removing or 
installing the clutch boss securing nut. 



YM-91 042 



90890-04086 





YM-41 16, 90890-04116 
YM-4097, 90890-04097 



Valve guide remover 
Intake 4.5 mm (0.18 in) 
Exhaust 5.0 mm (0.20 in) 

This tool is needed to remove and install the valve 
guide. 



YM-41 16 
YM-4097 



90890-04116 
90890-04097 





1 -8 



SPECIAL TOOLS 




Part number 



Tool name/How to use 



Illustration 



YM-41 17, 90890-04117 
YM-4098, 90890-04098 



Valve guide installer 
Intake 
Exhaust 



This tool is needed to install the valve guide. 



YM-41 17 
YM-4098 




90890-04117 
90890-04098 




YM-41 18, 90890-04118 
YM-4099, 90890-04099 



Valve guide reamer 
Intake 4.5 mm (0.18 in) 
Exhaust 5.0 mm (0.20 in) 



This tool is needed to rebore the new valve guide. 



YM-41 18 
YM-4099 




90890-04118 
90890-04099 




YM-34487 



90890-06754 



Dynamic spark tester 
Ignition checker 



This instrument is necessary for checking the ignition 
system components. 



YM-34487 



90890-06754 





ACC-QUICK-GS-KT 

90890-85505 



Quick gasket® 
YAMAHA Bond No. 1215 



This sealant (Bond) is used for crankcase mating 
surface, etc. 



ACC-QUICK-GS-KT 



90890-85505 





1 -9 



CONTROL FUNCTIONS 





EC1 50000 

CONTROL FUNCTIONS 

EC151000 

"ENGINE STOP" BUTTON 

The "ENGINE STOP" button © is located on 
the left handlebar. Continue pushing the 
"ENGINE STOP" button till the engine comes 
to a stop. 



EC1 52000 

CLUTCH LEVER 

The clutch lever © is located on the left han- 
dlebar; it disengages or engages the clutch. 
Pull the clutch lever to the handlebar to disen- 
gage the clutch, and release the lever to 
engage the clutch. The lever should be pulled 
rapidly and released slowly for smooth starts. 



EC1 53000 

SHIFT PEDAL 

The gear ratios of the constant-mesh 4 speed 
transmission are ideally spaced. The gears 
can be shifted by using the shift pedal © on 
the left side of the engine. 



EC1 54000 

KICK STARTER 

Rotate the kick starter © away from the 
engine. Push the starter down lightly with your 
foot until the gears engage, then kick smoothly 
and forcefully to start the engine. This model 
has a primary kick starter so the engine can be 
started in any gear if the clutch is disengaged. 
In normal practices, however, shift to neutral 
before starting. 

EC1 55001 

THROTTLE GRIP 

The throttle grip © is located on the right han- 
dlebar; it accelerates or decelerates the 
engine. For acceleration, turn the grip toward 
you; for deceleration, turn it away from you. 



1 -10 



CONTROL FUNCTIONS 





EC1 56000 

FRONT BRAKE LEVER 

The front brake lever © is located on the right 
handlebar. Pull it toward the handlebar to acti- 
vate the front brake. 



EC1 57000 

REAR BRAKE PEDAL 



The rear brake pedal © is located on the right 
side of the machine. Press down on the brake 
pedal to activate the rear brake. 







( -^z ^VT 





EC1 58001 

FUEL COCK 

The fuel cock supplies fuel from the tank to 
carburetor while filtering the fuel. The fuel cock 
has the two positions: 

OFF:With the lever in this position, fuel will not 
flow. Always return the lever to this posi- 
tion when the engine is not running. 
ON: With the lever in this position, fuel flows 
to the carburetor. Normal riding is done 
with the lever in this position. 
COLD STARTER KNOB 
When cold, the engine requires a richer air-fuel 
mixture for starting. A separate starter circuit, 
which is controlled by the cold starter knob ©, 
supplies this mixture. Pull the cold starter knob 
out to open the circuit for starting. When the 
engine has warmed up, push it in to close the 
circuit. 



HOT STARTER LEVER 

The hot starter lever © is used when starting a 
warm engine. 

Use the hot starter lever when starting the 
engine again immediately after it was stopped 
(the engine is still warm). Pulling the hot starter 
lever injects secondary air to thin the air-fuel 
mixture temporarily, allowing the engine to be 
started more easily. 



1 -11 



CONTROL FUNCTIONS 





^^^3^ 


^Slr 


i 




EC15R001 

DETACHABLE SIDESTAND 

This sidestand © is used to support only the 
machine when standing or transporting it. 



A WARNING 



• Never apply additional force to the side- 
stand. 

• Remove this sidestand before starting 
out. 

EC15F000 

VALVE JOINT 

This valve joint © prevents fuel from flowing 
out and is installed to the fuel tank breather 
hose. 

CAUTION: 

In this installation, make sure the arrow 
faces the fuel tank and also downward. 



SPARK PLUG WRENCH 

This spark plug wrench © is used to remove 
and install the spark plug. 



NIPPLE WRENCH 

This nipple wrench © is used to tighten the 
spoke. 



1 -12 




FUEL 



FUEL 

Always use the recommended fuel as stated 
below. Also, be sure to use new gasoline the 
day of a race. 



*o 



Recommended fuel: 

Except for ZA: 
Premium unleaded gasoline 
only with a research octane 
number of 95 or higher. 

For ZA: 
Premium gasoline 





Use only unleaded gasoline. The use of 
leaded gasoline will cause severe damage 
to the engine internal parts such as valves, 
piston rings, and exhaust system, etc. 

NOTE: 

If knocking or pinging occurs, use a different 
brand of gasoline or higher octane grade. 



A WARNING 



• For refueling, be sure to stop the engine 
and use enough care not to spill any fuel. 
Also be sure to avoid refueling close to a 
fire. 

• Refuel after the engine, exhaust pipe, etc. 
have cooled off. 



1 -13 



STARTING AND BREAK-IN 




STARTING AND BREAK-IN 



A WARNING 



Never start or run the engine in a closed 
area. The exhaust fumes are poisonous; 
they can cause loss of consciousness and 
death in a very short time. Always operate 
the machine in a well-ventilated area. 





• The carburetor on this motorcycle has a 
built-in accelerator pump. Therefore, 
when starting the engine, do not operate 
the throttle or the spark plug will foul. 

• Unlike a two-stroke engine, this engine 
cannot be kick started when the throttle is 
open because the kick starter may kick 
back. Also, if the throttle is open the air/ 
fuel mixture may be too lean for the 
engine to start. 

• Before starting the machine, perform the 
checks in the pre-operation check list. 




STARTING A COLD ENGINE 

1 . Inspect the coolant level. 

2. Turn the fuel cock to "ON". 

3. Shift the transmission into neutral. 

4. Fully open the cold starter knob ©. 

5. Kick the kick starter. 



A WARNING 



Do not open the throttle while kicking the 
kick starter. Otherwise, the kick starter may 
kick back. 



1 -14 



STARTING AND BREAK-IN 




6. Return the cold starter knob to its original 
position and run the engine at 3,000 ~ 
5,000 r/min for 1 or 2 minutes. 

NOTE: 

Since this model is equipped with an accelera- 
tor pump, if the engine is raced (the throttle 
opened and closed), the air/fuel mixture will be 
too rich and the engine may stall. Also unlike a 
two-stroke engine, this model can idle. 

CAUTION: 



Do not warm up the engine for extended 
periods of time. 



1 -15 



STARTING AND BREAK-IN 




(T) 











STARTING A WARM ENGINE 

Do not operate the cold starter knob and throt- 
tle. Pull the hot starter lever © and start the 
engine by kicking the kick starter forcefully with 
a firm stroke. 

As soon as the engine starts, release the hot 
starter lever to close the air passage. 

Restarting an engine after a fall 

Pull the hot starter lever and start the engine. 

As soon as the engine starts, release the hot 

starter lever to close the air passage. 

The engine fails to start 

Pull the hot starter lever all the way out and 

while holding the lever, kick the kick starter 10 

to 20 times to clear the engine. 

Then, restart the engine. 

Refer to "Restarting an engine after a fall". 







Throttle 
grip oper- 
ation* 


Cold 
starter 
knob 


Hot 
starter 
lever 


CD 

£Z 

CD 
■D 
O 
O 

CO 
O) 

c 
'■c 

CO 
00 


Air temperature = less than 
5 °C (41 °F) 


Open 3 
or 4 times 


ON 


OFF 


Air temperature = more 
than 5 °C (41 °F) 


None 


ON 


OFF 


Air temperature (normal tem- 
perature) = between 5 °C 
(41 °F) and 25 °C (77 °F) 


None 


ON/OFF 


OFF 


Air temperature = more 
than 25 °C (77 °F) 


None 


OFF 


OFF 


Starting an engine after a long 
period of time 


None 


ON 


OFF 


Restarting a warm engine 


None 


OFF 


ON 


Restarting an engine after a fall 


None 


OFF 


ON 



Operate the throttle grip before kick starting. 
CAUTION: 



Observe the following break-in procedures 
during initial operation to ensure optimum 
performance and avoid engine damage. 



1 -16 



STARTING AND BREAK-IN 




BREAK-IN PROCEDURES 

1. Before starting the engine, fill the fuel 
tank with the fuel. 

2. Perform the pre-operation checks on the 
machine. 

3. Start and warm up the engine. Check the 
idle speed, and check the operation of 
the controls and the "ENGINE STOP" 
button. Then, restart the engine and 
check its operation within no more than 5 
minutes after it is restarted. 

4. Operate the machine in the lower gears 
at moderate throttle openings for five to 
eight minutes. 

5. Check how the engine runs when the 
motorcycle is ridden with the throttle 1/4 
to 1/2 open (low to medium speed) for 
about one hour. 

6. Restart the engine and check the opera- 
tion of the machine throughout its entire 
operating range. Restart the machine 
and operate it for about 10 to 15 more 
minutes. The machine will now be ready 
to race. 



siiiiii 



• After the break-in or before each race, 
you must check the entire machine for 
loose fittings and fasteners as per 
"TORQUE-CHECK POINTS". 

Tighten all such fasteners as required. 

• When any of the following parts have 
been replaced, they must be broken in. 
CYLINDER AND CRANKSHAFT: 

About one hour of break-in operation is 
necessary. 

PISTON, RING, VALVES, CAMSHAFTS 
AND GEARS: 

These parts require about 30 minutes of 
break-in operation at half-throttle or less. 
Observe the condition of the engine care- 
fully during operation. 



1 -17 



TORQUE-CHECK POINTS 




TORQUE-CHECK POINTS 



Frame construction 



Combined seat and tank- 



Frame to rear frame 
Fuel tank to frame 



Exhaust system 



Silencer to rear frame 



Engine mounting 



Steering 



Steering shaft to 
handlebar 



- Frame to engine 

— Engine bracket to engine 

- Engine bracket to frame 

- Steering shaft to frame 

- Steering shaft to handle crown 
1 — Handle crown to handlebar 



Suspension 



Front Steering shaft to front ■ 

fork 



Rear For link type 



Rear 



-Rear 



-Installation of shock 
absorber 

-Installation of swing- 
arm 



n 



Front fork to handle crown 
Front fork to under bracket 



- Assembly of links 

- Link to frame 

— Link to shock absorber 

— Link to swingarm 

- Shock absorber to frame 



Tightening of pivot shaft 



Wheel 



-Installation of wheel 



-Front 
-Rear 



-i — Tightening of front axle 
' — Tightening of axle holder 
Tightening of rear axle 



n 



Wheel to sprocket 



Brake 



Fuel system 



Lubrication system 



Front 



-Rear 



Caliper to front fork 
Brake disc to wheel 
Tightening of union bolt 
Master cylinder to handlebar 
Tightening of air bleeder 

Brake pedal to frame 
Brake disc to wheel 
Tightening of union bolt 
Master cylinder to frame 
Tightening of air bleeder 

Fuel tank to fuel cock 

-Tightening of oil hose clamp 



NOTE: 

Concerning the tightening torque, refer to 
"MAINTENANCE SPECIFICATIONS" section 
in the CHAPTER 2. 



1 -18- 



CLEANING AND STORAGE 




EC1 B0000 

CLEANING AND STORAGE 

EC1B1000 

CLEANING 

Frequent cleaning of your machine will 
enhance its appearance, maintain good over- 
all performance, and extend the life of many 
components. 

1. Before washing the machine, block off 
the end of the exhaust pipe to prevent 
water from entering. A plastic bag 
secured with a rubber band may be used 
for this purpose. 

2. If the engine is excessively greasy, apply 
some degreaser to it with a paint brush. 
Do not apply degreaser to the chain, 
sprockets, or wheel axles. 

3. Rinse the dirt and degreaser off with a 
garden hose; use only enough pressure 
to do the job. 

CAUTION: 



Excessive hose pressure may cause water 
seepage and contamination of wheel bear- 
ings, front forks, brakes and transmission 
seals. Many expensive repair bills have 
resulted from improper high pressure 
detergent applications such as those avail- 
able in coin-operated car washers. 

4. After the majority of the dirt has been 
hosed off, wash all surfaces with warm 
water and a mild detergent. Use an old 
toothbrush to clean hard-to-reach places. 

5. Rinse the machine off immediately with 
clean water, and dry all surfaces with a 
soft towel or cloth. 

6. Immediately after washing, remove 
excess water from the chain with a paper 
towel and lubricate the chain to prevent 
rust. 

7. Clean the seat with a vinyl upholstery 
cleaner to keep the cover pliable and 
glossy. 



1 -19 



CLEANING AND STORAGE 




8. Automotive wax may be applied to all 
painted or chromed surfaces. Avoid com- 
bination cleaner-waxes, as they may con- 
tain abrasives. 

9. After completing the above, start the 
engine and allow it to idle for several min- 
utes. 



EC1B2001 

STORAGE 

If your machine is to be stored for 60 days or 
more, some preventive measures must be 
taken to avoid deterioration. After cleaning the 
machine thoroughly, prepare it for storage as 
follows: 

1. Drain the fuel tank, fuel lines, and the 
carburetor float bowl. 

2. Remove the spark plug, pour a table- 
spoon of SAE 10W-30 motor oil in the 
spark plug hole, and reinstall the plug. 
With the engine stop switch pushed in, 
kick the engine over several times to coat 
the cylinder walls with oil. 

3. Remove the drive chain, clean it thor- 
oughly with solvent, and lubricate it. 
Reinstall the chain or store it in a plastic 
bag tied to the frame. 

4. Lubricate all control cables. 

5. Block the frame up to raise the wheels off 
the ground. 

6. Tie a plastic bag over the exhaust pipe 
outlet to prevent moisture from entering. 

7. If the machine is to be stored in a humid 
or salt-air environment, coat all exposed 
metal surfaces with a film of light oil. Do 
not apply oil to rubber parts or the seat 
cover. 

NOTE: 

Make any necessary repairs before the 
machine is stored. 



1 -20 



GENERAL SPECIFICATIONS 



SPEC 



EC200000 

SPECIFICATIONS 

EC2 11000 

GENERAL SPECIFICATIONS 



Model name: 



YZ450FR (USA) 
YZ450F (EUROPE) 
YZ450F(R) (CDN, AUS, NZ, ZA) 



Model code number: 



5TA1 (USA) 

5TA2 (EUROPE) 

5TA4 (CDN, AUS, NZ, ZA) 



Dimensions: 
Overall length 
Overall width 
Overall height 
Seat height 
Wheelbase 
Minimum ground clearance 



2,171 mm (85.5 in) 
827 mm (32.6 in) 
1,303 mm (51.3 in) 
995 mm (39.2 in) 
1,485 mm (58.5 in) 
371 mm (14.6 in) 



Basic weight: 
With oil and full fuel tank 



113.0 kg (249 lb) 



Engine: 
Engine type 
Cylinder arrangement 
Displacement 
Bore x stroke 
Compression ratio 
Starting system 



Liquid cooled 4-stroke, DOHC 
Single cylinder, forward inclined 
449 cm 3 (15.8 Imp oz, 15.2 US oz) 
95.0 x 63.4 mm (3.74 x 2.50 in) 
12.5: 1 
Kick starter 



Lubrication system: 



Dry sump 



Oil type or grade: 
Engine oil 



Temp. 
40 50 




-20 
_L 



Temp. 
-10 10 
J I L 



20 
_L 



30 
_L 



40 
_L 



50 
J_ 



(For USA and CDN) 
At 5 °C (40 °F) or higher 
Yamalube 4 (20W-40) or SAE 20W-40 type SG 
motor oil (Non-Friction modified) 
At15 o C(60°F)orlower[|] 
Yamalube 4 (10W-30) or SAE 10W-30 type SG 
motor oil (Non-Friction modified) and/or 
Yamalube 4-R (15W-50) (Non-Friction modi- 
fied) 

(Except for USA and CDN) 
API "SG" or higher grade 











: : : iow-30 : 




| ■ ■ 10W-40 j 








15W-40 








20W-40 








20W-50 







14 



-I - 
30 



50 



- r - 

104 



122 



2-1 



GENERAL SPECIFICATIONS 



SPEC 



Oil capacity: 
Engine oil 
Periodic oil change 
With oil filter replacement 
Total amount 


1.0 L (0.88 Imp qt, 1.06 US qt) 

1.1 L (0.97 Imp qt, 1.16 US qt) 

1.2 L (1.06 Imp qt, 1.27 US qt) 


Coolant capacity (including all routes): 


1.2 L (1.06 Imp qt, 1.27 US qt) 


Air filter: 


Wet type element 


Fuel: 
Type 

Tank capacity 


Premium unleaded gasoline only with a research 
octane number of 95 or higher.(Except for ZA) 
Premium gasoline (For ZA) 
7.0 L (1 .54 Imp gal, 1 .85 US gal) 


Carburetor: 
Type 
Manufacturer 


FCR MX39 
KEIHIN 


Spark plug: 
Type/manufacturer 
Gap 


CR8E/NGK (resistance type) 
0.7 ~ 0.8 mm (0.028 ~ 0.031 in) 


Clutch type: 


Wet, multiple-disc 


Transmission: 

Primary reduction system 
Primary reduction ratio 
Secondary reduction system 
Secondary reduction ratio 
Transmission type 

Operation 
Gearratio: 1st 

2nd 

3rd 

4th 


USA, CDN, ZA, 
AUS, NZ 


EUROPE 


Gear 

62/22(2.818) 

Chain drive 

48/14(3.429) 

Constant mesh, 

4-speed 

Left foot operation 

27/14(1.929) 

25/16(1.563) 

23/18(1.278) 

21/20(1.050) 


<r~ 

47/14(3.357) 

<r~ 
<r~ 
<r~ 
<r~ 

<- 


Chassis: 
Frame type 
Caster angle 
Trail 


Semi double cradle 

27.2° 

118 mm (4.65 in) 


Tire: 
Type 
Size (front) 

Size (rear) 

Tire pressure (front and rear) 


With tube 

80/100-21 51 M (For USA, CDN, ZA, AUS, NZ 

and F) 

80/100-21 51 R (For EUROPE except F) 

110/90-19 62M (For USA, CDN, ZA, AUS, NZ 

and F) 

110/90-19 NHS (For EUROPE except F) 

100kPa(1.0kgf/cm 2 , 15 psi) 



2-2 



GENERAL SPECIFICATIONS 



SPEC 



Brake: 
Front brake type 
Operation 
Rear brake type 
Operation 


Single disc brake 
Right hand operation 
Single disc brake 
Right foot operation 


Suspension: 
Front suspension 
Rear suspension 


Telescopic fork 

Swingarm (link type monocross suspension) 


Shock absorber: 
Front shock absorber 
Rear shock absorber 


Coil spring/oil damper 
Coil spring/gas, oil damper 


Wheel travel: 
Front wheel travel 
Rear wheel travel 


300 mm (11.8 in) 
315 mm (12.4 in) 


Electrical: 
Ignition system 


CDI magneto 



2-3 



MAINTENANCE SPECIFICATIONS 



SPEC 



MAINTENANCE SPECIFICATIONS 

ENGINE 



Item 



Standard 



Limit 



Cylinder head: 
Warp limit 




0.05 mm 
(0.002 in) 



Cylinder: 
Bore size 

Out of round limit 



95.00 ~ 95.01 mm 
(3.7402 ~ 3.7406 in) 



0.05 mm 
(0.002 in) 



Camshaft: 
Drive method 
Camshaft cap inside diameter 

Camshaft journal diameter 

Shaft-to-cap clearance 

Cam dimensions 




Intake 



Exhaust 



"A" 
"B" 
"A" 
"B" 



Camshaft runout limit 




Chain drive (Left) 
22.000 ~ 22.021 mm 
(0.8661 ~ 0.8670 in) 
21.967 -21.980 mm 
(0.8648 ~ 0.8654 in) 
0.020 ~ 0.054 mm 
(0.0008 ~ 0.0021 in) 



31.200- 
(1 .2283 
22.550 - 
(0.8878 
30.950 - 
(1.2185 
22.494 - 
(0.8856 



- 31.300 mm 
~ 1 .2323 in) 

- 22.650 mm 
-0.8917 in) 

- 31.050 mm 
~ 1 .2224 in) 

- 22.594 mm 
~ 0.8895 in) 



0.08 mm 
(0.003 in) 



31.100 mm 
(1.2244 in) 
22.450 mm 
(0.8839 in) 
30.850 mm 
(1.2146 in) 
22.394 mm 
(0.8817 in) 
0.03 mm 
(0.0012 in) 



2-4 



MAINTENANCE SPECIFICATIONS 



SPEC 



Item 


Standard 


Limit 


Cam chain: 






Cam chain type/No. of links 


98XRH2010-118M/118 


— - 


Cam chain adjustment method 


Automatic 


— - 


Valve, valve seat, valve guide: 






Valve clearance (cold) IN 


0.10 ~ 0.15 mm 
(0.0039 ~ 0.0059 in) 


— 


EX 


0.20 ~ 0.25 mm 
(0.0079 ~ 0.0098 in) 


— 


Valve dimensions: 




A 




V\b 




Wo 


V 




r^ ^\ 


\^ 


\<\ 


\ 


( ) 
1- — a — H 


) \ 


) \ 


) 


_D 




t 


Head Diameter Face Width 


Seat Width Margin Thickness 


"A" head diameter IN 


26.9 ~ 27.1 mm 
(1.0591 ~ 1.0669 in) 


— 


EX 


27.9 ~ 28.1 mm 
(1.0984- 1.1063 in) 


— 


"B" face width IN 


2.26 mm (0.089 in) 


— - 


EX 


2.26 mm (0.089 in) 




"C" seat width IN 


0.9 ~ 1.1 mm 


1.6 mm 




(0.0354 ~ 0.0433 in) 


(0.0630 in) 


EX 


0.9 ~ 1.1 mm 


1.6 mm 




(0.0354 ~ 0.0433 in) 


(0.0630 in) 


"D" margin thickness IN 


1 mm (0.0394 in) 


0.85 mm 
(0.033 in) 


EX 


1 mm (0.0394 in) 


0.85 mm 
(0.033 in) 


Stem outside diameter IN 


4.475 ~ 4.490 mm 


4.445 mm 




(0.1762 -0.1768 in) 


(0.1750 in) 


EX 


4.965 ~ 4.980 mm 


4.935 mm 




(0.1955-0.1961 in) 


(0.1943 in) 


Guide inside diameter IN 


4.500 ~ 4.512 mm 


4.550 mm 




(0.1772 -0.1776 in) 


(0.1791 in) 


EX 


5.000 ~ 5.012 mm 


5.050 mm 




(0.1969 -0.1973 in) 


(0.1988 in) 


Stem-to-guide clearance IN 


0.010 ~ 0.037 mm 


0.08 mm 




(0.0004 -0.0015 in) 


(0.003 in) 


EX 


0.020 ~ 0.047 mm 


0.10 mm 




(0.0008 -0.0019 in) 


(0.004 in) 


Stem runout limit 


— 


0.01 mm 
(0.0004 in) 


0? 








- 


kl— 1 




1 — k-m m\ 












^ O 


///////////////////// 













2-5 



MAINTENANCE SPECIFICATIONS 



SPEC 



Item 



Standard 



Limit 



Valve spring: 
Free length 



Set length (valve closed) 

Compressed force 
(installed) 



Tilt limit* 



IN 

EX 

IN 
EX 

IN 

EX 

IN 
EX 



37.03 mm (1.46 in) 

37.68 mm (1.48 in) 

27.87 mm (1.10 in) 
27.38 mm (1.08 in) 



111.3- 127.9 Nat 27.87 mm 
(11.3- 13.0 kg at 27.87 mm, 
24.91 -28.66 lb at 1.10 in) 

127.4- 146.4 Nat 27.38 mm 
(13.0- 14.9 kg at 27.38 mm, 
28.66 - 32.85 lb at 1 .08 in) 



35.17 mm 
(1.38 in) 
35.79 mm 
(1.41 in) 




Direction of winding 
(top view) 



IN 
EX 



Clockwise 
Clockwise 



2.571.61mm 
(2.570.063 in) 
2.571 .65 mm 
(2.570.065 in) 



Piston: 
Piston to cylinder clearance 

Piston size "D" 



0.040 - 0.065 mm 
(0.0016 -0.0026 in) 
94.945 - 94.960 mm 
(3.738 - 3.739 in) 




Measuring point "H" 

Piston off-set 

Piston pin bore inside diameter 

Piston pin outside diameter 



8 mm (0.315 in) 
1 mm (0.0394 in) 
18.004- 18.015 mm 
(0.7088 - 0.7093 in) 
17.991 - 18.000 mm 
(0.7083 - 0.7087 in) 



0.1 mm 
(0.004 in) 



18.045 mm 
(0.7104 in) 
17.971 mm 
(0.7075 in) 



2-6 



MAINTENANCE SPECIFICATIONS 



SPEC 



Item 


Standard 


Limit 


Piston rings: 
Top ring: 






Barrel 

1.2x3.5 mm (0.05 x 0.14 in) 

0.20 ~ 0.30 mm 

(0.008 -0.012 in) 

0.030 ~ 0.065 mm 

(0.0012 -0.0026 in) 

Taper 

1.00x3.35 mm (0.04x0.13 in) 

0.35 ~ 0.50 mm 

(0.014 -0.020 in) 

0.020 ~ 0.055 mm 

(0.0008 ~ 0.0022 in) 

2.0x2.9 mm (0.08x0.11 in) 
0.2 ~ 0.5 mm (0.01 ~ 0.02 in) 


0.55 mm 
(0.022 in) 
0.12 mm 
(0.005 in) 

0.85 mm 
(0.033 in) 
0.12 mm 
(0.005 in) 




) 


B 


T 


Type 

Dimensions (B x T) 

End gap (installed) 

Side clearance (installed) 

2nd ring: 








\ 


B 


T 




Type 

Dimensions (B x T) 

End gap (installed) 

Side clearance 

Oil ring: 




_ 


^=f 


B 


1 i i 


T 




Dimensions (B x T) 
End gap (installed) 




Crankshaft: 
Crank width "A" j 

Runout limit "C" k 

(xid_ 
Big end side clearance "D" ; 

Small end free play "F" ^ 


C 


61.95 ~ 62.00 mm 
(2.439 ~ 2.441 in) 
0.03 mm (0.0012 in) 

0.15 ~ 0.45 mm 

(0.0059 -0.0177 in) 

0.4 ~ 1 .0 mm (0.02 ~ 0.04 in) 


0.05 mm 
(0.002 in) 
0.50 mm 
(0.02 in) 
2.0 mm 
(0.08 in) 


Balancer: 
Balancer drive method 


Gear 





Air filter oil grade: 


Foam-air-filter oil or equivalent oil 





2-7 



MAINTENANCE SPECIFICATIONS 



SPEC 



Item 


Standard 


Limit 


Clutch: 








Friction plate thickness 




2.92 ~ 3.08 mm 


2.8 mm 






(0.115-0.121 in) 


(0.110 in) 


Quantity 




9 




Clutch plate thickness 




1.1 ~ 1.3 mm (0.043 -0.051 in) 




Quantity 




8 




Warp limit 




— 


0.1 mm 
(0.004 in) 


Clutch spring free length 




50 mm (1.97 in) 


49 mm 
(1.93 in) 


Quantity 




6 




Clutch housing thrust clearance 




0.10 ~ 0.35 mm 
(0.0039 -0.0138 in) 





Clutch housing radial clearance 




0.010 ~ 0.044 mm 
(0.0004 -0.0017 in) 





Clutch release method 




Inner push, cam push 


— - 


Shifter: 








Shifter type 




Cam drum and guide bar 




Guide bar bending limit 




— 


0.05 mm 
(0.002 in) 


Kick starter: 








Type 




Ratchet type 


— - 


Carburetor: 








1. D. mark 




5TA1 00 


— - 


Main jet 


(M.J) 


#165 


— - 


Main air jet 


(M.A.J) 


#200 


— - 


Jet needle - clip position 


(J.N) 


NCVQ-4 


— - 


Cutaway 


(C.A) 


1.5 


— - 


Pilot jet 


(P.J) 


#42 


— - 


Pilot air jet 


(P.A.J) 


#100 


— - 


Pilot outlet 


(P.O) 


00.9 


— - 


Pilot screw (example) 


(P.S) 


2 


— - 


Bypass 


(B.P) 


01.0 


— - 


Valve seat size 


(V.S) 


03.8 


— - 


Starter jet 


(G.S) 


#72 


— - 


Float height 


(F.H) 


8 mm (0.31 in) 


— - 


Engine idle speed 




1,900- 2,100 r/min 


— - 


Intake vacuum 




28.0 ~ 33.3 kPa (210 ~ 250 mmHg, 
8.27 ~ 9.84 inHg) 


— 


Hot starter lever free play 




3~6mm (0.12 ~ 0.24 in) 


— - 



2-8 



MAINTENANCE SPECIFICATIONS 



SPEC 



Item 



Standard 



Limit 



Lubrication system: 
Oil filter type 
Oil pump type 
Tip clearance "A" 

Tip clearance "B" 

Side clearance 

Bypass valve setting pressure 



-^^B 




Wire mesh type 

Trochoid type 

0.12 mm or less 

(0.0047 in or less) 

0.09 ~ 0.17 mm 

(0.0035 ~ 0.0067 in) 

0.03- 0.10 mm 

(0.0012 -0.0039 in) 

40 ~ 80 kPa (0.4 ~ 0.8 kg/cm 2 

5.69- 11.38 psi) 



0.20 mm 
(0.008 in) 
0.24 mm 
(0.009 in) 
0.17 mm 
(0.007 in) 



Cooling: 
Radiator core size 

Width 

Height 

Thickness 
Radiator cap opening pressure 
Radiator capacity (total) 
Water pump 

Type 



117.8 mm (4.6 in) 
260 mm (10.2 in) 
32 mm (1.26 in) 
110kPa(1.1 kg/cm 2 , 15.6 psi) 
0.71 L (0.62 Imp qt, 0.75 US qt) 

Single-suction centrifugal pump 



2-9 



MAINTENANCE SPECIFICATIONS 



SPEC 



Item 



Standard 



Lubrication chart: 

i j S Pressure feed 
^ Splashed scavenge 



fl 



3£ 



Transmission gears 



Main axle 



lz 



Drive axle 



Cylinder head 



Oil filter 



Check ball 



Oil pump rotor 1 ^ 



Oil pump rotor 2 

— 7^ — 



Oil strainer 



a 



Camshaft 



Valve lifter 






Piston 



^ Piston pin 



Crank pin 



V V V 



Oil tank 

7T 



Oil pan 



2-10 



MAINTENANCE SPECIFICATIONS 



SPEC 





Part to be tightened 


Thread size 


Q'ty 


Tightening torque 




Nm 


m-kg 


ft-lb 




Spark plug 


M10Sx1.0 


1 


13 


1.3 


9.4 




Camshaft cap 


M6x1.0 


10 


10 


1.0 


7.2 




Cylinder head blind plug screw 


M12x1.0 


1 


37 


3.7 


27 




Cylinder head (stud bolt) 


M6x1.0 


2 


7 


0.7 


5.1 






M8x1.25 


1 


15 


1.5 


11 




(bolt) 


M10x1.25 


4 


Refer to NOT 


"E.* 1 




(nut) 


M6x1.0 


2 


10 


1.0 


7.2 




Cylinder head cover 


M6x1.0 


2 


10 


1.0 


7.2 




Cylinder 


M6x1.0 


1 


10 


1.0 


7.2 




Timing chain tensioner 


M6x1.0 


2 


10 


1.0 


7.2 




Tensioner cap bolt 


M6x1.0 


1 


7 


0.7 


5.1 




Timing chain guide (rear) 


M6x1.0 


2 


10 


1.0 


7.2 




Exhaust pipe (nut) 


M8x1.25 


1 


13 


1.3 


9.4 




(bolt) 


M8x1.25 


1 


24 


2.4 


17 


A 


Silencer 


M8x1.25 


2 


35 


3.5 


25 




Silencer clamp 


M8x1.25 


1 


20 


2.0 


14 




Exhaust pipe protector 


M6x1.0 


3 


10 


1.0 


7.2 




Clamp (cylinder head side) 


M5x0.8 


1 


3 


0.3 


2.2 




Clamp (carburetor side) 


M4 x 0.7 


1 


3 


0.3 


2.2 




Air filter case 


M6x1.0 


2 


8 


0.8 


5.8 




Air filter joint clamp 


M6x1.0 


1 


3 


0.3 


2.2 




Air filter joint and air filter case 


M5x0.8 


1 


4 


0.4 


2.9 




Throttle cable cover 


M5x0.8 


2 


4 


0.4 


2.9 




Hot starter plunger 


M12x1.0 


1 


2 


0.2 


1.4 




Air filter element 


M6x1.0 


1 


2 


0.2 


1.4 




Radiator panel (upper) 


M6x1.0 


2 


10 


1.0 


7.2 




Radiator 


M6x1.0 


6 


10 


1.0 


7.2 




Radiator hose clamp 


M6x1.0 


8 


2 


0.2 


1.4 




Radiator pipe 1 , 2 


M10x1.0 


2 


10 


1.0 


7.2 




Impeller 


M8x1.25 


1 


14 


1.4 


10 




Water pump housing cover 


M6x1.0 


3 


10 


1.0 


7.2 




Coolant drain bolt 


M6x1.0 


1 


10 


1.0 


7.2 




Oil pump cover 


M4 x 0.7 


1 


3 


0.3 


2.2 




Oil pump 


M6x1.0 


3 


10 


1.0 


7.2 




Engine oil drain bolt (oil filter) 


M6x1.0 


1 


10 


1.0 


7.2 




Oil filter cover 


M6x1.0 


2 


10 


1.0 


7.2 




Oil delivery pipe 1 


M10x1.25 


1 


20 


2.0 


14 






M8x1.25 


2 


18 


1.8 


13 




Oil delivery pipe 2 


M6x1.0 


1 


10 


1.0 


7.2 




Oil hose 


M6x1.0 


2 


10 


1.0 


7.2 




Oil check bolt 


M6x1.0 


1 


10 


1.0 


7.2 


A 


Oil hose clamp 


- 


2 


2 


0.2 


1.4 




Clutch cover 


M6x1.0 


7 


10 


1.0 


7.2 



2-11 



MAINTENANCE SPECIFICATIONS 



SPEC 



Part to be tightened 


Thread size 


Q'ty 


Tightening torque 


Nm 


mkg 


ft-lb 


Crankcase cover (right) 


M6x1.0 


10 


10 


1.0 


7.2 


Crankcase cover (left) 


M6x1.0 


8 


10 


1.0 


7.2 


Crankcase 


M6x1.0 


12 


12 


1.2 


8.7 


Clutch cable holder 


M6x1.0 


1 


10 


1.0 


7.2 


Oil drain bolt (crankcase rear) 


M10x1.25 


1 


20 


2.0 


1.4 


(crankcase left) 


M6x1.0 


1 


10 


1.0 


7.2 


Oil drain bolt (frame) 


M8x1.25 


1 


23 


2.3 


17 


Oil strainer (frame) 


M18x1.5 


1 


90 


9.0 


65 


Crankcase bearing stopper 


M6x1.0 


15 


10 


1.0 


7.2 


Drive axle oil seal stopper 


M6x1.0 


2 


10 


1.0 


7.2 


Ratchet wheel guide 


M6x1.0 


2 


12 


1.2 


8.7 


Stopper plate 


M6x1.0 


2 


12 


1.2 


8.7 


Kick starter 


M8x1.25 


1 


33 


3.3 


24 


Screw (kick starter) 


M6x1.0 


1 


7 


0.7 


5.1 


Primary drive gear 


M20x1.0 


1 


75 


7.5 


54 


Clutch boss 


M20x1.0 


1 


75 


7.5 


54 


Push lever 


M6x1.0 


1 


10 


1.0 


7.2 


Clutch spring 


M6x1.0 


6 


8 


0.8 


5.8 


Balancer driven gear 


M14x1.0 


1 


50 


5.0 


36 


Balancer weight plate 


M6x1.0 


3 


10 


1.0 


7.2 


Drive sprocket 


M20x1.0 


1 


75 


7.5 


54 


Drive sprocket cover 


M6x1.0 


2 


8 


0.8 


5.8 


Shift pedal 


M6x1.0 


1 


12 


1.2 


8.7 


Shift guide 


M6x1.0 


2 


10 


1.0 


7.2 


Stopper lever 


M6x1.0 


1 


10 


1.0 


7.2 


Segment 


M8x1.25 


1 


30 


3.0 


22 



NOTE: 

A- marked portion shall be checked for torque tightening after break-in or before each race. 

NOTE: 

*1 : Tighten the cylinder head bolts to 30 Nm (3.0 m • kg, 22 ft • lb) in the proper tightening sequence, 
remove and retighten the cylinder head bolts to 20 Nm (2.0 m • kg, 14 ft • lb) in the proper tightening 
sequence, and then tighten the cylinder head bolts further to reach the specified angle 180° in the 
proper tightening sequence. 



2-12 



MAINTENANCE SPECIFICATIONS 



SPEC 



EC212201 

CHASSIS 



Item 


Standard 


Limit 


Steering system: 






Steering bearing type 


Taper roller bearing 




Front suspension: 






Front fork travel 


300 mm (11.8 in) 


— - 


Fork spring free length 


460 mm (18.1 in) 


455 mm (17.9 in) 


Spring rate, STD 


K = 4.51 N/mm 

(0.46 kg/mm, 25.8 lb/in) 


— 


Optional spring/spacer 


Yes 


— - 


Oil capacity 


568 cm 3 

(20.0 Imp oz, 19.2 US oz) 


— 


Oil level 


135 mm (5.31 in) 


— - 


<Min.~Max.> 


80- 150 mm (3.15 -5.91 in) 


— 


(From top of outer tube with inner 






tube and damper rod fully com- 






pressed without spring.) 






Oil grade 


Suspension oil "01" 


— - 


Inner tube outer diameter 


46 mm (1.81 in) 




Front fork top end 


Zero mm (Zero in) 


— - 


Rear suspension: 


USA, CDN, 


EUROPE 




Shock absorber travel 


AUS, NZ, ZA 




.... 


132 mm 


<r~ 




(5.20 in) 






Spring free length 


260 mm 


275 mm 






(10.24 in) 


(10.83 in) 




Fitting length 


249 mm 


264 mm 


— - 




(9.80 in) 


(10.39 in) 




<Min.~Max.> 


240.5 -258.5 mm 


255.5 -273.5mm 






(9.47 -10.18 in) 


(10.06 -10.77 in) 




Spring rate, STD 


K = 52.0 N/mm 


K = Approx. 


— - 




(5.30 kg/mm, 


52.0 N/mm 






296.8 lb/in) 


(5.30 kg/mm, 
296.8 lb/in) 




Optional spring 


Yes 


<- 




Enclosed gas pressure 


1 ,000 kPa 
(10 kg/cm 2 , 
142 psi) 


<- 




Swingarm: 






Swingarm free play limit 






End 




1.0 mm (0.04 in) 



2-13 



MAINTENANCE SPECIFICATIONS 



SPEC 



Item 


Standard 


Limit 


Wheel: 






Front wheel type 


Spoke wheel 




Rear wheel type 


Spoke wheel 


— - 


Front rim size/material 


21 x 1.60/Aluminum 


— - 


Rear rim size/material 


19x2.15/Aluminum 




Rim runout limit: 






Radial 


— - 


2.0 mm (0.08 in) 


Lateral 




2.0 mm (0.08 in) 


Drive chain: 


USA, CDN, 


EUROPE 




Type/manufacturer 


AUS, NZ, ZA 







DID520DMA2 


<- 




SDH/DAIDO 






Number of links 


113 links + joint 


111 links + joint 


— - 


Chain slack 


40 ~ 50 mm 
(1.6 -2.0 in) 


<- 


— 


Chain length (10 links) 




<- 


152.5 mm (6.00 in) 


Front disc brake: 






Disc outside dia. x Thickness 


250 x 3.0 mm (9.84 x 0.12 in) 


250x2.5 mm 
(9.84x0.10 in) 


Pad thickness 


4.4 mm (0.17 in) 


1.0 mm (0.04 in) 


Master cylinder inside dia. 


11.0 mm (0.433 in) 


— - 


Caliper cylinder inside dia. 


27.0 mm (1.063 in) x2 




Brake fluid type 


DOT #4 


— - 


Rear disc brake: 






Disc outside dia. x Thickness 


245 x 4.0 mm (9.65 x 0.16 in) 


245 x 3.5 mm 
(9.65x0.14 in) 


Deflection limit 




0.15 mm (0.006 in) 


Pad thickness 


6.4 mm (0.25 in) 


1.0 mm (0.04 in) 


Master cylinder inside dia. 


11.0 mm (0.433 in) 




Caliper cylinder inside dia. 


25.4 mm (1.000 in) x 1 


— - 


Brake fluid type 


DOT #4 




Brake lever and brake pedal: 






Brake lever position 


95 mm (3.74 in) 


— - 


Brake pedal height 


5 mm (0.20 in) 




(vertical height above footrest top) 






Clutch lever free play (lever end) 


8~ 13 mm (0.31 -0.51 in) 


— - 


Throttle grip free play 


3 ~ 5 mm (0.12 ~ 0.20 in) 


— - 



2-14 



MAINTENANCE SPECIFICATIONS 



SPEC 





Part to be tightened 


Thread size 


Q'ty 


Tightening torque 




Nm 


m-kg 


ft-lb 


A 


Handle crown and outer tube 


M8x1.25 


4 


23 


2.3 


17 


A 


Under bracket and outer tube 


M8x1.25 


4 


20 


2.0 


14 


A 


Handle crown and steering shaft 


M24 x 1 .0 


1 


145 


14.5 


105 


A 


Handlebar holder (upper) 


M8x1.25 


4 


28 


2.8 


20 


A 


Steering ring nut 


M28 x 1 .0 


1 


Refer to NOl 


"E. 




Front fork and cap bolt 


M48 x 1 .0 


2 


30 


3.0 


22 




Front fork and base valve 


M30 x 1 .0 


2 


55 


5.5 


40 




Cap bolt and damper rod (front fork) 


M12x1.25 


2 


29 


2.9 


21 




Bleed screw (front fork) and cap bolt 


M5 x 0.8 


2 


1 


0.1 


0.7 




Front fork and protector 


M6x1.0 


6 


10 


1.0 


7.2 




Front fork and brake hose holder 


M6x1.0 


2 


10 


1.0 


7.2 




Front fork and hose cover 


M8x1.25 


1 


16 


1.6 


11 




Front fork and hose cover 


M6x1.0 


1 


7 


0.7 


5.1 




Throttle cable cap 


M5x0.8 


2 


4 


0.4 


2.9 




Clutch lever holder mounting 


M5 x 0.8 


2 


4 


0.4 


2.9 




Clutch lever mounting 


M6x1.0 


1 


2 


0.2 


1.4 




Hot starter lever holder mounting 


M5 x 0.8 


2 


4 


0.4 


2.9 


A 


Front brake master cylinder and bracket 


M6x1.0 


2 


9 


0.9 


6.5 




Front brake master cylinder cap 


M4 x 0.7 


2 


2 


0.2 


1.4 




Brake lever mounting (bolt) 


M6x1.0 


1 


6 


0.6 


4.3 




Brake lever mounting (nut) 


M6x1.0 


1 


6 


0.6 


4.3 




Brake lever position locknut 


M6x1.0 


1 


5 


0.5 


3.6 




Cable guide (front brake hose) and guide stay 


M5 x 0.8 


1 


4 


0.4 


2.9 


A 


Front brake hose union bolt (master cylinder) 


M10x1.25 


1 


30 


3.0 


22 


A 


Front brake hose union bolt (caliper) 


M10x1.25 


1 


30 


3.0 


22 


A 


Front brake caliper and front fork 


M8x1.25 


2 


23 


2.3 


17 


A 


Brake caliper (front and rear) and pad pin plug 


M10x1.0 


1 


3 


0.3 


2.2 


A 


Brake caliper (front and rear) and pad pin 


M10x1.0 


1 


18 


1.8 


13 


A 


Brake caliper (front and rear) and bleed screw 


M8x1.25 


1 


6 


0.6 


4.3 


A 


Front wheel axle and nut 


M16x1.5 


1 


105 


10.5 


75 


A 


Front wheel axle holder 


M8x1.25 


4 


23 


2.3 


17 


A 


Front brake disc and wheel hub 


M6x1.0 


6 


12 


1.2 


8.7 


A 


Rear brake disc and wheel hub 


M6x1.0 


6 


14 


1.4 


10 


A 


Brake pedal mounting 


M8x1.25 


1 


26 


2.6 


19 


A 


Rear brake master cylinder and frame 


M6x1.0 


2 


11 


1.1 


8.0 




Rear brake master cylinder cap 


M4x0.7 


2 


2 


0.2 


1.4 


A 


Rear brake hose union bolt (caliper) 


M10x1.25 


1 


30 


3.0 


22 


A 


Rear brake hose union bolt (master cylinder) 


M10x1.25 


1 


30 


3.0 


22 



NOTE: 

1. First, tighten the ring nut approximately 38 Nm (3.8 m • kg, 27 ft • lb) by using the ring nut 
wrench, then loosen the ring nut one turn. 

2. Retighten the ring nut 7 Nm (0.7 m • kg, 5.1 ft • lb). 



2-15 



MAINTENANCE SPECIFICATIONS 



SPEC 





Part to be tightened 


Thread size 


Q'ty 


Tightening torque 




Nm 


m-kg 


ft-lb 


A 


Rear wheel axle and nut 


M20 x 1 .5 


1 


125 


12.5 


90 


A 


Driven sprocket and wheel hub 


M8x1.25 


6 


42 


4.2 


30 


A 


Nipple (spoke) 


- 


72 


3 


0.3 


2.2 




Disc cover and rear brake caliper 


M6x1.0 


2 


7 


0.7 


5.1 




Protector and rear brake caliper 


M6x1.0 


2 


7 


0.7 


5.1 




Chain puller adjust bolt and locknut 


M8x1.25 


2 


16 


1.6 


11 




Engine mounting: 












A 


Engine upper bracket and frame 


M10x1.25 


2 


55 


5.5 


40 


A 


Engine lower bracket and frame 


M8x1.25 


4 


34 


3.4 


24 


A 


Engine and frame (front) 


M10x1.25 


1 


65 


6.5 


47 


A 


Engine and frame (upper) 


M10x1.25 


1 


55 


5.5 


40 


A 


Engine and frame (lower) 


M10x1.25 


1 


69 


6.9 


50 




Engine guard (lower) 


M8x1.25 


1 


23 


2.3 


17 




Engine skid plate mounting 


M6x1.0 


6 


10 


1.0 


7.2 




CDI unit bracket mounting 


M6x1.0 


1 


10 


1.0 


7.2 


A 


Pivot shaft and nut 


M16x1.5 


1 


85 


8.5 


61 


A 


Relay arm and swingarm 


M14x1.5 


1 


80 


8.0 


58 


A 


Relay arm and connecting rod 


M14x1.5 


1 


80 


8.0 


58 


A 


Connecting rod and frame 


M14x1.5 


1 


80 


8.0 


58 


A 


Rear shock absorber and frame 


M10x1.25 


1 


56 


5.6 


40 


A 


Rear shock absorber and relay arm 


M10x1.25 


1 


53 


5.3 


38 


A 


Rear frame and frame (upper) 


M8x1.25 


1 


32 


3.2 


23 


A 


Rear frame and frame (lower) 


M8x1.25 


2 


29 


2.9 


21 




Swingarm and brake hose holder 


M5x0.8 


4 


1 


0.1 


0.7 




Swingarm and patch 


M4 x 0.7 


4 


2 


0.2 


1.4 




Drive chain tensioner mounting (upper) 


M8x1.25 


1 


19 


1.9 


13 




Drive chain tensioner mounting (lower) 


M8x1.25 


1 


20 


2.0 


14 




Chain support and swingarm 


M6x1.0 


3 


7 


0.7 


5.1 


A 


Seal guard and swingarm 


M5 x 0.8 


4 


6 


0.6 


4.3 


A 


Fuel tank mounting 


M6x1.0 


2 


10 


1.0 


7.2 


A 


Fuel tank and fuel cock 


M6x1.0 


2 


7 


0.7 


5.1 




Fuel tank and seat set bracket 


M6x1.0 


1 


7 


0.7 


5.1 




Fuel tank and hooking screw (fitting band) 


M6x1.0 


1 


7 


0.7 


5.1 




Fuel tank and fuel tank bracket 


M6x1.0 


4 


7 


0.7 


5.1 




Seat mounting 


M8x1.25 


2 


23 


2.3 


17 




Side cover mounting 


M6x1.0 


2 


7 


0.7 


5.1 




Air scoop and fuel tank 


M6x1.0 


6 


4 


0.4 


2.9 




Air scoop and radiator panel (lower) 


M6x1.0 


2 


4 


0.4 


2.9 




Front fender mounting 


M6x1.0 


4 


7 


0.7 


5.1 




Rear fender mounting (front) 


M6x1.0 


2 


7 


0.7 


5.1 




Rear fender mounting (rear) 


M6x1.0 


2 


10 


1.0 


7.2 




Number plate 


M6x1.0 


1 


7 


0.7 


5.1 



NOTE: 

A- marked portion shall be checked for torque tightening after break-in or before each race. 

2-16 



MAINTENANCE SPECIFICATIONS 



SPEC 



EC2 12300 

ELECTRICAL 



Item 


Standard 


Limit 


Ignition system: 
Advancer type 


Electrical 





C.D.I. : 
Magneto-model (stator)/manufacturer 
Source coil 1 resistance (color) 

Source coil 2 resistance (color) 

Pickup coil resistance (color) 

CDI unit-model/manufacturer 


5SF-00/YAMAHA 

720- 1 5 080Qat20°C(68°F) 

(Green - Brown) 

44 ~ 66 Q at 20 °C (68 °F) 

(Black - Pink) 

248 ~ 372 Q at 20 °C (68 °F) 

(White - Red) 

5TA-00/YAMAHA 


— - 


Ignition coil: 
Model/manufacturer 
Minimum spark gap 
Primary winding resistance 
Secondary winding resistance 


5TA-00/DENSO 
6 mm (0.24 in) 

0.08~0.10Qat20°C(68°F) 
4.6 ~ 6.8 kQ at 20 °C (68 °F) 


— - 



Part to be tightened 


Thread size 


Q'ty 


Tightening torque 


Nm 


m-kg 


ft-lb 


Stator 
Rotor 
Neutral switch 


M6x1.0 

M12x1.25 

M5x0.8 


3 
1 
2 


10 
56 

4 


1.0 
5.6 
0.4 


7.2 
40 
2.9 



2-17 



GENERAL TORQUE SPECIFICATIONS/ 

DEFINITION OF UNITS 



SPEC 



EC220001 

GENERAL TORQUE SPECIFICATIONS 

This chart specifies torque for standard fasten- 
ers with standard I.S.O. pitch threads. Torque 
specifications for special components or 
assemblies are included in the applicable sec- 
tions of this book. To avoid warpage, tighten 
multi-fastener assemblies in a crisscross fash- 
ion, in progressive stages, until full torque is 
reached. Unless otherwise specified, torque 
specifications call for clean, dry threads. Com- 
ponents should be at room temperature. 









TORQUE 




A 
(Nut) 


B 
(Bolt) 


SPECIFICATION 


Nm 


m*kg 


ft*lb 


10 mm 


6 mm 


6 


0.6 


4.3 


12 mm 


8 mm 


15 


1.5 


11 


14 mm 


10 mm 


30 


3.0 


22 


17 mm 


12 mm 


55 


5.5 


40 


19 mm 


14 mm 


85 


8.5 


61 


22 mm 


16 mm 


130 


13 


94 




A: Distance between flats 
B: Outside thread diameter 



EC230000 

DEFINITION OF UNITS 



Unit 


Read 


Definition 


Measure 


mm 
cm 


millimeter 
centimeter 


1 0" 3 meter 
1 2 meter 


Length 
Length 


kg 


kilogram 


10 3 gram 


Weight 


N 


Newton 


1 kg x m/sec 2 


Force 


Nm 
m • kg 


Newton meter 
Meter kilogram 


N x m 
m x kg 


Torque 
Torque 


Pa 


Pascal 


N/m 2 


Pressure 


N/mm 


Newton per millimeter 


N/mm 


Spring rate 


L 
cm 3 


Liter 

Cubic centimeter 


— 


Volume or capacity 
Volume or capacity 


r/min 


Revolution per minute 


— 


Engine speed 



2-18 



LUBRICATION DIAGRAMS 



SPEC 



LUBRICATION DIAGRAMS 

© Oil delivery pipe 
© Intake camshaft 
© Exhaust camshaft 
© Oil cleaner element 
© Oil pump 
© Main axle 
© Drive axle 




2-19 



LUBRICATION DIAGRAMS 



SPEC 



© Camshaft 

© Connecting rod 

© Oil cleaner element 

© Crankshaft 

© Main axle 

© Drive axle 

© Oil delivery pipe 



g^^^Oq 




Jj^^ SaJS^ ^ ' 



3 







M\ 




2-20 



CABLE ROUTING DIAGRAM 




EC240000 

CABLE ROUTING DIAGRAM 

© Fuel tank breather hose 
© Hot starter cable 
© Radiator hose 4 
© Cylinder head breather hose 
© Radiator hose 1 
© Oil tank breather hose 
© Hose guide 
© Brake hose 

© "ENGINE STOP" button lead 
© Clamp 

© Sub wire harness 
© TPS (throttle position sen- 
sor) lead 
© Neutral switch lead 
© Oil hose 

© Radiator breather hose 
© CDI magneto lead 



© Carburetor breather hose 
© Overflow hose 

[a] Pass the fuel tank breather hose 
between the handlebar and ten- 
sion bar, then insert its end into 
the hole of the number plate. 

[H Pass the hot starter cable 
between the cylinder head 
breather hose, oil tank breather 
hose and ignition coil, then on 
the outside of the left engine 
bracket. 

\c\ Pass the cylinder head breather 
hose on the outside of the radia- 
tor hose 1 and on the inside of the 
radiator pipe (radiator hose 4). 



\d\ Fit the brake hose into the 
guides on the protector. 

B Fasten the "ENGINE STOP" 
button lead and sub wire har- 
ness to the frame with a plastic 
locking tie and cut off the tie 
end. 

\E\ Fasten the sub wire harness 
and hot starter cable to the 
frame at the white tape for the 
sub wire harness with a plastic 
locking tie and cut off the tie 
end. 

M Fasten the sub wire harness to 
the frame with a plastic locking 
tie and cut off the tie end. 




2-21 



CABLE ROUTING DIAGRAM 




ED Pass the sub wire harness 

between the engine brackets. 
CD Make sure that the TPS lead 

coupler does not go outside the 

chassis. 
El Fasten the TPS lead to the 

frame with a plastic band. 
\K\ Fasten the neutral switch lead 

and oil hose together with a 

plastic locking tie and cut off 

the tie end. 
B Fasten the neutral switch lead 

to the frame with a plastic 

band. 
M Fasten the neutral switch lead, 

CDI magneto lead and radiator 

breather hose to the frame with 

a plastic band. 



M Pass the neutral switch lead, 
CDI magneto lead and radiator 
breather hose between the 
radiator and frame. 

\Q\ Fasten the neutral switch lead 
and CDI magneto lead to the 
cable guide with a plastic lock- 
ing tie and cut off the tie end. 

\E Pass the carburetor breather 
hoses and overflow hose so 
that all there hoses do not con- 
tact the rear shock absorber. 



Decompression cable (sup- 
plied for Europe and optional 
for other destinations) 
Pass the decompression cable 
under the middle radiator 
mounting boss and on the out- 
side of the neutral switch lead, 
CDI magneto lead and radiator 
breather hose. 




2-22 



CABLE ROUTING DIAGRAM 




© Cable holder 

© CDI unit 

© Hot starter cable 

© Clutch cable 

© Throttle cable (return) 

© Throttle cable (pull) 

© Ignition coil 

© Radiator breather hose 

© Radiator hose 4 

© Cylinder head breather 

hose 
© CDI unit bracket 
(J2) CDI unit band 



[a] Fasten the grommet of the clutch 
cable with the cable holder. 

\b\ Pass the hot starter cable, clutch 
cable and throttle cables through 
the cable guides. 

\c\ Pass the hot starter cable over the 
top radiator mounting boss. 

\o\ Pass the hot starter cable, clutch 
cable and throttle cables between 
the radiator and frame, then over 
the middle radiator mounting 
boss. 

\E\ Pass the clutch cable and throttle 
cables on the outside of the igni- 
tion coil. 

[E Pass the radiator breather hose at 
the rear of the radiator, on the left 
of the chassis, and then between 
the frame and radiator hose 4. 



\g\ Insert the CDI unit band over the 
CDI unit bracket as far as possi- 
ble. 

ED First install the CDI unit and CDI 
unit band to the CDI unit bracket, 
then the CDI unit bracket to the 
frame. 




2-23 



CABLE ROUTING DIAGRAM 




© Master cylinder 
© Brake hose holder 
(3) Brake hose 



[a] Install the brake hose so that its 
pipe portion directs as shown and 
lightly touches the projection on 
the caliper. 

\b\ Pass the brake hose into the 
brake hose holders. 

\c\ If the brake hose contacts the 
spring (rear shock absorber), cor- 
rect its twist. 

\d\ Install the brake hose so that its 
pipe portion directs as shown and 
lightly touches the projection on 
the master cylinder. 




2-24 



CABLE ROUTING DIAGRAM 



SPEC 



© Throttle cable 

© Fuel tank breather hose 

© Clamp 

© Clutch cable 

© Hot starter cable 

© "ENGINE STOP" button lead 

© Brake hose 

© Hose guide 



[a] Fasten the "ENGINE STOP" but- 
ton lead to the handlebar with the 
plastic band. 

H] Pass the brake hose in front of the 
number plate. 

\c\ Pass the hot starter cable, clutch 
cable and throttle cables through 
the cable guide. 



Decompression cable (supplied 
for Europe and optional for other 
destinations) 




2-25 



MAINTENANCE INTERVALS 



INSP 
ADJ 



<& 



EC300000 



REGULAR INSPECTION AND ADJUSTMENTS 

MAINTENANCE INTERVALS 

The following schedule is intended as a general guide to maintenance and lubrication. Bear in mind 
that such factors as weather, terrain, geographical location, and individual usage will alter the 
required maintenance and lubrication intervals. If you are a doubt as to what intervals to follow in 
maintaining and lubricating your machine, consult your Yamaha dealer. 



Item 


After 
break-in 


Every 
race 


Every 

third 

(or 

500 km) 


Every 

fifth 

(or 

1 ,000 km) 


As re- 
quired 


Remarks 


ENGINE OIL 
Replace 


• 












OIL FILTER 
Clean 


• 












VALVES 
Check the valve clearances 
Inspect 
Replace 


• 




• 




• 


The engine must be cold. 
Check the valve seats 
and valve stems for wear. 


VALVE SPRINGS 
Inspect 
Replace 










• 


Check the free length and 
the tilt. 


VALVE LIFTERS 
Inspect 
Replace 










• 


Check for scratches and 
wear. 


CAMSHAFTS 
Inspect 
Replace 










• 


Inspect the camshaft sur- 
face. 

Inspect the decompres- 
sion system 


CAMSHAFT SPROCKETS 
Inspect 
Replace 










• 


Check for wear on the 
teeth and for damage. 


PISTON 
Inspect 
Clean 
Replace 










• 
• 
• 


Inspect crack 

Inspect carbon deposits 

and eliminate them. 


PISTON RING 
Inspect 
Replace 










• 


Check ring end gap 


PISTON PIN 
Inspect 
Replace 










• 




CYLINDER HEAD 
Inspect and clean 












Inspect carbon deposits 
and eliminate them. 
Change gasket 


CYLINDER 
Inspect and clean 
Replace 










• 


Inspect score marks 
Inspect wear 


CLUTCH 
Inspect and adjust 
Replace 


• 


• 






• 


Inspect housing, friction 
plate, clutch plate and 
spring 


TRANSMISSION 
Inspect 
Replace bearing 










• 
• 





3-1 



MAINTENANCE INTERVALS 




Item 


After 
break-in 


Every 
race 


Every 

third 

(or 

500 km) 


Every 

fifth 

(or 

1 ,000 km) 


As re- 
quired 


Remarks 


SHIFT FORK, SHIFT CAM, GUIDE BAR 
Inspect 










• 


Inspect wear 


ROTOR NUT 
Retighten 


• 






• 






MUFFLER 
Inspect and retighten 
Clean 
Replace 


• 


• 




• 


• 


* Whichever comes first 


CRANK 
Inspect and clean 








• 


• 




CARBURETOR 
Inspect, adjust and clean 


• 


• 








When using a high-pres- 
sure washer, make sure 
that water does not enter 
the accelerator pump. 


SPARK PLUG 
Inspect and clean 
Replace 


• 




• 




• 




DRIVE CHAIN 
Lubricate, slack, alignment 
Replace 


• 








• 


Use chain lube 
Chain slack: 40 ~ 50 mm 
(1.6 -2.0 in) 


COOLING SYSTEM 
Check coolant level and leakage 
Check radiator cap operation 
Replace coolant 
Inspect hoses 


• 








• 
• 


Every two years 


OUTSIDE NUTS AND BOLTS 
Retighten 


• 










Refer to "STARTING 
AND BREAK-IN" section 
in the CHAPTER 1. 


AIR FILTER 
Clean and lubricate 
Replace 


• 








• 


Use foam air-filter oil or 
equivalent oil 


OIL FILTER 
Replace 


• 






• 






OIL STRAINER (frame) 
Clean 








• 






FRAME 
Clean and inspect 


• 


• 










FUEL TANK, COCK 
Clean and inspect 


• 




• 








BRAKES 
Adjust lever position and pedal height 
Lubricate pivot point 
Check brake disc surface 
Check fluid level and leakage 
Retighten brake disc bolts, caliper 
bolts, master cylinder bolts and union 
bolts 

Replace pads 
Replace brake fluid 


• 
• 
• 
• 
• 








• 
• 


Every one year 


FRONT FORKS 
Inspect and adjust 
Replace oil 
Replace oil seal 


• 
• 


• 




• 


• 


Suspension oil "01" 



3-2 



MAINTENANCE INTERVALS 



INSP 
ADJ 



<& 



Item 


After 
break-in 


Every 
race 


Every 

third 

(or 

500 km) 


Every 

fifth 

(or 

1 ,000 km) 


As re- 
quired 


Remarks 


FRONT FORK OIL SEAL AND DUST 
SEAL 
Clean and lube 












Lithium base grease 


REAR SHOCK ABSORBER 
Inspect and adjust 
Lube 
Retighten 






• 




(After 
rain ride) 

• 


Molybdenum disulfide 
grease 


CHAIN GUARD AND ROLLERS 
Inspect 














SWINGARM 
Inspect, lube and retighten 












Molybdenum disulfide 
grease 


RELAY ARM, CONNECTING ROD 
Inspect, lube and retighten 












Molybdenum disulfide 
grease 


STEERING HEAD 
Inspect free play and retighten 
Clean and lube 
Replace bearing 








• 


• 


Lithium base grease 


TIRE, WHEELS 
Inspect air pressure, wheel run-out, 
tire wear and spoke looseness 
Retighten sprocket bolt 
Inspect bearings 
Replace bearings 
Lubricate 






• 
• 




• 


Lithium base grease 


THROTTLE, CONTROL CABLE 
Check routing and connection 
Lubricate 












Yamaha cable lube or 
SAE 10W-30 motor oil 


HOT STARTER, CLUTCH LEVER 
Inspect free play 










• 





3-3 



PRE-OPERATION INSPECTION AND MAINTENANCE 



INSP 
ADJ 



<& 



EC320000 

PRE-OPERATION INSPECTION AND MAINTENANCE 

Before riding for break-in operation, practice or a race, make sure the machine is in good operating 

condition. 

Before using this machine, check the following points. 

GENERAL INSPECTION AND MAINTENANCE 



Item 


Routine 


Page 


Coolant 


Check that coolant is filled up to the radiator filler cap. 
Check the cooling system for leakage. 


P.3-5 ~ 9 


Fuel 


Check that a fresh gasoline is filled in the fuel tank. Check the 
fuel line for leakage. 


P.1-13 


Engine oil 


Check that the oil level is correct. Check the crankcase and 
frame oil line for leakage. 


P.3-13- 17 


Gear shifter and clutch 


Check that gears can be shifted correctly in order and that the 
clutch operates smoothly. 


P.3-9 


Throttle grip/Housing 


Check that the throttle grip operation and free play are correctly 
adjusted. Lubricate the throttle grip and housing, if necessary. 


P.3-10 


Brakes 


Check the play of front brake and effect of front and rear brake. 


P.3-24 ~ 30 


Chain 


Check chain slack and alignment. Check that the chain is lubri- 
cated properly. 


P.3-31 ~ 33 


Wheels 


Check for excessive wear and tire pressure. Check for loose 
spokes and have no excessive play. 


P.3-41 ~ 42 


Steering 


Check that the handlebar can be turned smoothly and have no 
excessive play. 


P.3-42 ~ 43 


Front forks and rear shock 
absorber 


Check that they operate smoothly and there is no oil leakage. 


P.3-33 ~ 40 


Cables (wires) 


Check that the clutch and throttle cables move smoothly. Check 
that they are not caught when the handlebars are turned or 
when the front forks travel up and down. 


— 


Muffler 


Check that the muffler is tightly mounted and has no cracks. 


— 


Sprocket 


Check that the driven sprocket tightening bolt is not loose. 


P.3-31 


Lubrication 


Check for smooth operation. Lubricate if necessary. 


P.3-44 


Bolts and nuts 


Check the chassis and engine for loose bolts and nuts. 


P.1-18 


Lead connectors 


Check that the CDI magneto, CDI unit, and ignition coil are con- 
nected tightly. 


P. 1-6 


Settings 


Is the machine set suitably for the condition of the racing course 
and weather or by taking into account the results of test runs 
before racing? Are inspection and maintenance completely 
done? 


P.7-1 -21 



3-4 



ENGINE/COOLANT LEVEL INSPECTION 



INSP 
ADJ 



<& 




EC350000 

ENGINE 

EC351011 

COOLANT LEVEL INSPECTION 



A WARNING 



Do not remove the radiator cap ©, drain 
bolt and hoses when the engine and radia- 
tor are hot. Scalding hot fluid and steam 
may be blown out under pressure, which 
could cause serious injury. 
When the engine has cooled, place a thick 
towel over the radiator cap, slowly rotate 
the cap counterclockwise to the detent. 
This procedure allows any residual pres- 
sure to escape. When the hissing sound 
has stopped, press down on the cap while 
turning counterclockwise and remove it. 



MMMmMMM 

Hard water or salt water is harmful to the 
engine parts. You may use distilled water, if 
you can't get soft water. 




1 . Place the machine on a level place, and 
hold it in an upright position. 

2. Remove: 

• Radiator cap 

3. Check: 

• Coolant level ® 

Coolant level low -^ Add coolant. 
© Radiator 



3-5 



COOLANT REPLACEMENT 



INSP 
ADJ 



<& 



EC35301 1 

COOLANT REPLACEMENT 



A WARNING 



Do not remove the radiator cap when the 
engine is hot. 




II 

Take care so that coolant does not splash 
on painted surfaces. If it splashes, wash it 
away with water. 

1 . Place a container under the engine. 

2. Remove: 

• Engine guard © 

• Coolant drain bolt ® 

3. Remove: 

• Radiator cap 

Drain the coolant completely. 

4. Clean: 

• Cooling system 

Thoroughly flush the cooling system 
with clean tap water. 

5. Install: 

• Copper washer 

• Coolant drain bolt 



10 Nm (1.0 m kg, 7.2 ft lb) 



• Engine guard 

• Bolt (engine guard) 



34 Nm (3.4 m • kg, 24 ft • lb) 




6. Fill: 

• Radiator 

• Engine 



To specified level. 



K} 



Recommended coolant: 
High quality ethylene glycol 
anti-freeze containing anti- 
corrosion for aluminum engine 

Coolant © and water (soft water) ® 

mixing ratio: 
50 %/50 % 

Coolant capacity: 
1.2 L (1.06 Imp qt, 1.27 US qt) 



3-6 



RADIATOR CAP INSPECTION 



INSP 
ADJ 



<& 



11 

• Do not mix more than one type of ethyl- 
ene glycol antifreeze containing corro- 
sion inhibitors for aluminum engine. 

• Do not use water containing impurities or 
oil. 



Handling notes of coolant: 

The coolant is harmful so it should be han- 
dled with special care. 



A WARNING 



• When coolant splashes to your eye. 
Thoroughly wash your eye with water 
and see your doctor. 

• When coolant splashes to your clothes. 
Quickly wash it away with water and 
then with soap. 

• When coolant is swallowed. 

Quickly make him vomit and take him 
to a doctor. 



7. Install: 

• Radiator cap 

Start the engine and warm it up for a 
several minutes. 

8. Check: 

• Coolant level 

Coolant level low -> Add coolant. 




EC355000 

RADIATOR CAP INSPECTION 

1. Inspect: 

• Seal (radiator cap) © 

• Valve and valve seat © 
Crack/damage -> Replace. 

Exist fur deposits © -» Clean or 
replace. 



3-7 



RADIATOR CAP OPENING PRESSURE INSPECTION/ 

COOLING SYSTEM INSPECTION 



INSP 



ADJ 



<& 




EC356001 

RADIATOR CAP OPENING PRESSURE 
INSPECTION 

1. Attach: 

• Radiator cap tester © and adapter i 



/> 



Radiator cap tester: 

YU-24460-01/90890-01 325 
Adapter: 

YU-33984/90890-01352 



NOTE: 

Apply water on the radiator cap seal. 

® Radiator cap 
2. Apply the specified pressure. 




Radiator cap opening pressure: 
110 kPa(1.1 kg/cm 2 , 15.6 psi) 



3. Inspect: 
• Pressure 
Impossible to maintain the specified 
pressure for 10 seconds -^ Replace. 




EC357002 

COOLING SYSTEM INSPECTION 

1. Inspect: 

• Coolant level 

2. Attach: 

• Radiator cap tester © and adapter < 



/- 



Radiator cap tester: 

YU-24460-01/90890-01 325 
Adapter: 

YU-33984/90890-01352 



3. Apply the specified pressure. 




Standard pressure: 
180 kPa (1.8 kg/cm 2 , 25.6 psi) 



3-8 



CLUTCH ADJUSTMENT 



INSP 
ADJ 



<& 



NOTE: 

• Do not apply pressure more than specified 
pressure. 

• Radiator should be filled fully. 



® 

J 


r 










i { C\^^_^- 


vo^T 


( 


:( jj 


4j,- 


Jf^u^ 


V 







4. Inspect: 

• Pressure 

Impossible to maintain the specified 
pressure for 10 seconds -> Repair. 

• Radiator 

• Radiator hose joint 

Coolant leakage -^ Repair or replace. 

• Radiator hose 
Swelling -^ Replace. 

EC359020 

CLUTCH ADJUSTMENT 

1. Check: 

• Clutch lever free play ® 

Out of specification -^ Adjust. 




Clutch lever free play ®: 
8-13 mm (0.31 -0.51 in) 




2. Adjust: 

• Clutch lever free play 



Clutch lever free play adjustment steps: 

• Loosen the locknut ©. 

• Turn the adjuster © until free play ® is 
within the specified limits. 

• Tighten the locknut. 



NOTE: 

• Make minute adjustment on the lever side 
using the adjuster ©. 

• After adjustment, check proper operation of 
clutch lever. 



3-9 



THROTTLE CABLE ADJUSTMENT/ 
THROTTLE LUBRICATION 



INSP 



ADJ 



<& 




EC35A001 

THROTTLE CABLE ADJUSTMENT 

1. Check: 

• Throttle grip free play ® 
Out of specification -^ Adjust. 




Throttle grip free play ®: 
3-5 mm (0.12 ~ 0.20 in) 



2. Adjust: 

• Throttle grip free play 



Throttle grip free play adjustment steps: 

• Slide the adjuster cover. 

• Loosen the locknut ©. 

• Turn the adjuster ® until the specified free 
play is obtained. 

• Tighten the locknut. 

NOTE: 

Before adjusting the throttle cable free play, 
the engine idle speed should be adjusted. 



A WARNING 



After adjusting, turn the handlebar to 
right and left and make sure that the 
engine idling does not run faster. 





^S^ 


M^k 


J 


=Mr 








M 


II m 




T 


1f^ 




THROTTLE LUBRICATION 

1 . Remove: 

• Cover (throttle cable cap) © 

• Cover (grip cap) © 

• Throttle cable cap (3) 



Apply: 

• Lithium soap base grease 
On the throttle cable end ®. 

Install: 

• Throttle cable cap 

• Screw (throttle cable cap) 



4 Nm (0.4 m • kg, 2.9 ft • lb) 



• Cover (grip cap) 

• Cover (throttle cable cap) 



3-10 



HOT STARTER LEVER ADJUSTMENT/ 
AIR FILTER CLEANING 



INSP 



ADJ 



<& 




HOT STARTER LEVER ADJUSTMENT 

1. Check: 

• Hot starter lever free play ® 
Out of specification -^ Adjust. 




Hot starter lever free play ®: 
3-6 mm (0.12 ~ 0.24 in) 



2. Adjust: 

• Hot starter lever free play 



Hot starter lever free play adjustment 
steps: 

• Loosen the locknut ©. 

• Turn the adjuster © until free play ® is 
within the specified limits. 

• Tighten the locknut. 



NOTE: 

After adjustment, check proper operation of 
hot starter. 



EC35G040 

AIR FILTER CLEANING 
NOTE: 



Proper air filter maintenance is the biggest key 
to preventing premature engine wear and 
damage. 







Never run the engine without the air filter 
element in place; this would allow dirt and 
dust to enter the engine and cause rapid 
wear and possible engine damage. 



1 . Remove: 

• Seat 

• Fitting bolt © 

• Washer © 

• Air filter element 

• Filter guide © 



3-11 



AIR FILTER CLEANING 



INSP 
ADJ 



<& 




2. Clean: 

• Air filter element 
Clean them with solvent. 

NOTE: 



After cleaning, remove the remaining solvent 
by squeezing the element. 

€AU 



• Do not twist the element when squeezing 
the element. 

• Leaving too much of solvent in the ele- 
ment may result in poor starting. 

3. Inspect: 

• Air filter element 
Damage -» Replace. 

4. Apply: 

• Foam-air-filter oil or equivalent oil to the 
element. 

NOTE: 

Squeeze out the excess oil. Element should 
be wet but not dripping. 




5. Install: 

• Filter guide © 

NOTE: 



Align the projection ® on filter guide with the 
hole (6) in air filter element. 



6. Apply: 

• Lithium soap base grease 
On the matching surface ® on air filter 
element. 



3-12 



ENGINE OIL LEVEL INSPECTION 



INSP 
ADJ 



<& 




7. Install: 

• Air filter element © 

• Washer 

• Fitting bolt 



2 Nm (0.2 m - kg, 1.4ft- lb) 



NOTE: 

Align the projection ® on filter guide with the 
hole© in air filter case. 



ENGINE OIL LEVEL INSPECTION 

1 . Stand the motorcycle on a level surface. 

NOTE: 

• When checking the oil level make sure that 
the motorcycle is upright. 

• Place the motorcycle on a suitable stand. 



A WARNING 



Never remove the oil tank cap just after 
high speed operation. The heated oil could 
spurt out. causing danger. Wait until the oil 
cools down to approximately 70 °C (158 °F). 

2. Idle the engine more than 3 minutes 
while keeping the motorcycle upright. 
Then stop the engine and inspect the oil 
level. 




3. Remove: 

• Oil tank cap © 



3-13 



ENGINE OIL LEVEL INSPECTION 



INSP 
ADJ 



<& 




4. Inspect: 
• Oil level 
Oil level should be between maximum 
® and minimum (b) marks. 
Oil level low -^ Add oil to proper level. 

NOTE: 

When inspecting the oil level, do not screw the 
oil level gauge into the oil tank. 
Insert the gauge lightly. 

(For USA and CDN) 




Recommended oil: 
At 5 °C (40 °F) or higher S 
Yamalube 4 (20W-40) or SAE 
20W-40 type SG motor oil 
(Non-Friction modified) 
At 15 °C (60 °F) or lower \E 
Yamalube 4 (10W-30) or SAE 
10W-30 type SG motor oil 
(Non-Friction modified) 
and/or 

Yamalube 4-R(15W-50) 
(Non-Friction modified) 



Temp. °C 

-20-10 10 20 30 40 50 





! ! ! ! 








: : iow-3o : 




; j 10W-40 j 






: : : 15W-40 






: : : 20W-40 






: ; ; 20W-50 






I I I I I I I I 

-4 14 30 50 68 86 104 122 o 



1 1 

• Do not add any chemical additives. 
Engine oil also lubricates the clutch and 
additives could cause clutch slippage. 

• Do not allow foreign material to enter the 
crankcase. 

(Except for USA and CDN) 




Recommended oil: 
Refer to the following chart for 
selection of oils which are suited 
to the atmospheric temperatures. 
Recommended engine oil classi- 
fication: 

API STANDARD: 
API "SG" or higher grade 
(Designed primarily for motor- 
cycles) 






• Do not add any chemical additives or use 
oils with a grade of CD ® or higher. 

• Do not use oils labeled "ENERGY CON- 
SERVING II" © or higher. Engine oil also 
lubricates the clutch and additives could 
cause clutch slippage. 

• Do not allow foreign materials to enter the 
crankcase. 



3-14 



ENGINE OIL REPLACEMENT 



INSP 
ADJ 



<& 



Start the engine and let it warm up for 
several minutes. 



mmi&mm 




When the oil tank is empty, never start the 
engine. 

6. Idle the engine more than 10 seconds 
while keeping the motorcycle upright. 
Then stop the engine and add the oil to 
the maximum level. 

7. Install: 

• Oil tank cap 
ENGINE OIL REPLACEMENT 

1. Start the engine and let it warm up for 
several minutes. 

2. Stop the engine and place an oil pan 
under the drain bolt. 

3. Remove: 

• Oil tank plug © 

• Oil filler cap © 

• Drain bolt (with gasket) © 

• Oil filter drain bolt (O-ring) © 

• Drain bolt (with gasket) © 

• Drain bolt (with gasket) © 

Drain the crankcase and oil tank 
(frame) of its oil. 



Remove: 

• Engine skid plate 

• Engine oil hose clamp © 

• Bolt (engine oil hose) © 

• Engine oil hose © 

• Oil strainer (frame) @ 
Clean: 

• Oil strainer (frame) 



3-15 



ENGINE OIL REPLACEMENT 



INSP 
ADJ 



<& 




6. If the oil filter is to be replaced during this 
oil change, remove the following parts 
and reinstall them. 



Replacement steps: 

• Remove the exhaust pipe. 

• Remove the oil filter cover © and oil filter 
element ©. 

• Check the O-rings ©, if cracked or dam- 
aged, replace them with a new one. 

• Install the oil filter element and oil filter 
cover. 



Oil filter cover: 
10 Nm (1.0 itt kg, 7.2 ft •lb) 



7. Install: 

• Plain washer © 

• Oil strainer (frame) © 

| \ |90 Nm (9.0 m • kg, 65 ft • lb)" 

• Engine oil hose © 

• Bolt (engine oil hose) @ 



|\ |10 Nm (1.0 m- kg, 7.2 ft • lb) 



Engine oil hose clamp © 



2 Nm (0.2 m kg, 1.4 ft lb) 



• Engine skid plate 
8. Install: 

• Gaskets E^3 

• Oil filter drain bolt 

|\ |10 Nm (1.0 m- kg, 7.2 ft • lb)" 

• Drain bolt (crankcase rear) 



|\ |20 Nm (2.0 m • kg, 14 ft • lb) 



• Drain bolt (crankcase left) 

|\ |10 Nm (1.0 m • kg, 7.2 ft • lb) 

• Drain bolt (frame) 



23 Nm (2.3 m -kg, 17 ft -lb) 



9. Fill: 

• Crankcase 



*o 



Oil quantity: 
Total amount: 

1.2 L (1.06 Imp qt, 1.27 US qt) 
Periodic oil change: 

1.0 L (0.88 Imp qt, 1.06 US qt) 
With oil filter replacement: 

1.1 L (0.97 Imp qt, 1.16 US qt) 



3-16 



10. Install: 

• Oil filler plug 

11. Inspect: 

• Engine (for oil leaks) 

• Oil level 

Refer to "ENGINE OIL LEVEL INSPEC- 
TION". 



PILOT SCREW ADJUSTMENT 



INSP 
ADJ 



<& 




12. Check: 

• Oil pressure 



Checking steps: 

• Slightly loosen the oil gallery bolt ©. 

• Start the engine and keep it idling until oil 
starts to seep from the oil gallery bolt. If no 
oil comes out after one minute, turn the 
engine off so it will not seize. 

• Check oil passages, oil filter and oil pump 
for damage or leakage. 

• Start the engine after solving the prob- 
lem^) and recheck the oil pressure. 

• Tighten the oil gallery bolt to specification. 



Oil gallery bolt: 
10 Nm (1.0 or kg, 7.2 ft •lb) 




PILOT SCREW ADJUSTMENT 

1. Adjust: 

• Pilot screw © 



Adjusting steps: 
NOTE: 



To optimize the fuel flow at a smaller throttle 
opening, each machine's pilot screw has 
been individually set at the factory. Before 
adjusting the pilot screw, turn it in fully and 
count the number of turns. Record this num- 
ber as the factory-set number of turns out. 

• Turn in the pilot screw until it is lightly 
seated. 

• Turn out the pilot screw by the factory-set 
number of turns. 




Pilot screw: 
2 turns out (example) 



3-17 



IDLE SPEED ADJUSTMENT/ 
VALVE CLEARANCE ADJUSTMENT 



INSP 



ADJ 



<& 




EC35M021 

IDLE SPEED ADJUSTMENT 

1 . Start the engine and thoroughly warm it 
up. 

2. Adjust: 

• Idle speed 



Adjustment steps: 

• Adjust the pilot screw. 

Refer to "PILOT SCREW ADJUSTMENT" 
section. 

• Turn the throttle stop screw © until the 
engine runs at the lowest possible speed. 



To increase idle speed -^ 

Turn the throttle stop screw © in (a). 
To decrease idle speed -^ 
Turn the throttle stop screw © out ©. 




Engine idling speed: 
1,900 ~ 2,100 r/min 




VALVE CLEARANCE ADJUSTMENT 

NOTE: 

• The valve clearance should be adjusted 
when the engine is cool to the touch. 

• The piston must be at Top Dead Center 
(T.D.C.) on compression stroke to check or 
adjust the valve clearance. 

1 . Remove: 

• Seat 

• Fuel tank 

Refer to "SEAT, FUEL TANK AND SIDE 
COVERS" section in the CHAPTER 4. 

2. Remove: 

• Carburetor 

Refer to "CARBURETOR" section in 
the CHAPTER 4. 

• Spark plug cap 

• Engine stay (upper) 

• Cylinder head cover 

Refer to "CAMSHAFTS" section in the 
CHAPTER 4. 

3. Remove: 

• Timing plug © 

• Straight plug © 

• O-ring 



3-18 



VALVE CLEARANCE ADJUSTMENT 



INSP 
ADJ 



<& 



4. Check: 

• Valve clearance 
Out of specification -^ Adjust. 



Valve clearance (cold): 
Intake valve: 

0.10 ~ 0.15 mm (0.0039 ~ 0.0059 in) 
Exhaust valve: 

0.20 ~ 0.25 mm (0.0079 ~ 0.0098 in) 







Checking steps: 

• Turn the crankshaft counterclockwise with 
a wrench. 

• Align the T.D.C. mark ® on the rotor with 
the align mark © on the crankcase cover 
when piston is at T.D.C. on compression 
stroke. 

NOTE: 

In order to be sure that the piston is at Top 
Dead Center, the punch mark © on the 
exhaust camshaft and the punch mark 0) on 
the intake camshaft must align with the cyl- 
inder head surface, as shown in the illustra- 
tion. 



• Measure the valve clearance (§) using a 
feeler gauge ©. 

NOTE: 

Record the measured reading if the clear- 
ance is incorrect. 




3-19 



VALVE CLEARANCE ADJUSTMENT 



INSP 
ADJ 



<& 














EX 


® ® 

O O 




IN 


© ® ® 

o o o 











^o 



Adjust: 

• Valve clearance 



Adjustment steps: 

• Loosen the timing chain tensioner cap 
bolt. 

• Remove the timing chain tensioner and 
camshaft caps. 

NOTE: 

Remove the camshaft cap bolts in a criss- 
cross pattern from the outside working 
inwards. 

• Remove the camshaft (exhaust © and 
intake ©). 

NOTE: 

Attach a wire (3) to the timing chain to pre- 
vent it from falling into the crankcase. 

• Remove the valve lifters (3) and the pads 0. 

NOTE: 

• Place a rag in the timing chain space to 
prevent pads from falling into the crank- 
case. 

• Identity each valve lifter and pad position 
very carefully so that they can be rein- 
stalled in their original place. 

• Select the proper pad using the pad 
selecting table. 



Pad range 



No. 120 
No. 240 



1.20 mm 
2.40 mm 



Pad Availability: 
25 increments 



Pads are available in 
0.05 mm increments 



NOTE: 

The thickness ® of each pad is indicated in 
hundreths of millimeters on the pad upper 
surface. 



3-20 



VALVE CLEARANCE ADJUSTMENT 



INSP 
ADJ 



<& 




• Round off the last digit of the installed pad 
number to the nearest increment. 



Last digit of pad 
number 



0, 1 or 2 



4, 5 or 6 



8 or 9 



Rounded value 



10 



EXAMPLE: 

Installed pad number = 148 
Rounded off value = 150 

NOTE: 



Pads can only be selected in 0.05 mm incre- 
ments. 

• Locate the rounded-off value and the mea- 
sured valve clearance in the chart "PAD 
SELECTION TABLE". The field where 
these two coordinates intersect shows the 
new pad number to use. 

NOTE: 

Use the new pad number only as a guide 
when verifying the valve clearance adjust- 
ment. 

• Install the new pads (§) and the valve lift- 
ers (§). 

NOTE: 



• Apply the engine oil on the valve lifters. 

• Apply the molybdenum disulfide oil on the 
valve stem ends. 

• Valve lifter must turn smoothly when 
rotated with a finger. 

• Be careful to reinstall valve lifters and 
pads in their original place. 

• Install the camshafts (exhaust and intake), 
the timing chain and the camshaft caps. 
Refer to "CAMSHAFTS" section in the 
CHAPTER 4. 



\ 



Bolt (camshaft cap): 
10 Nm (1.0 m •kg, 7.2 ft • lb) 



3-21 



VALVE CLEARANCE ADJUSTMENT 



INSP 
ADJ 



<& 



• Install the timing chain tensioner. 

Refer to "CAMSHAFTS" section in the 
CHAPTER 4. 

NOTE: 

Turn the crankshaft counterclockwise sev- 
eral turns so that the installed parts settle 
into the right position. 

• Recheck the valve clearance. 

• If the clearance is still incorrect, repeat all 
the clearance adjustment steps until the 
specified clearance is obtained. 



6. Install: 

• All removed parts 



NOTE: 

Install all removed parts in reversed order of 
their removal. Note the following points. 



3-22 



VALVE CLEARANCE ADJUSTMENT 




INTAKE 



MEASURED 
CLEARANCE 


INSTALLED PAD NUMBER 


120 


125 


130 


135 


140 


145 


150 


155 


160 


165 


170 


175 


180 


185 


190 


195 


200 


205 


210 


215 


220 


225 


230 


235 


240 


0.00- 


-0.04 






120 


125 


130 


135 


140 


145 


150 


155 


160 


165 


170 


175 


180 


185 


190 


195 


200 


205 


210 


215 


220 


225 


230 


0.05- 


-0.09 




120 


125 


130 


135 


140 


145 


150 


155 


160 


165 


170 


175 


180 


185 


190 


195 


200 


205 


210 


215 


220 


225 


230 


235 


0.10- 


-0.15 


STANDARD CLEARANCE 


0.16- 


-0.20 


125 


130 


135 


140 


145 


150 


155 


160 


165 


170 


175 


180 


185 


190 


195 


200 


205 


210 


215 


220 


225 


230 


235 240 




0.21 - 


-0.25 


130 


135 


140 


145 


150 


155 


160 


165 


170 


175 


180 


185 


190 


195 


200 


205 


210 


215 


220 


225 


230 


235 


240 






0.26- 


-0.30 


135 


140 


145 


150 


155 


160 


165 


170 


175 


180 


185 


190 


195 


200 


205 


210 


215 


220 


225 


230 


235 


240 






0.31 - 


-0.35 


140 


145 


150 


155 


160 


165 


170 


175 


180 


185 


190 


195 


200 


205 


210 


215 


220 


225 


230 


235 


240 






0.36- 


-0.40 


145 


150 


155 


160 


165 


170 


175 


180 


185 


190 


195 


200 


205 


210 


215 


220 


225 


230 


235 


240 






0.41 - 


-0.45 


150 


155 


160 


165 


170 


175 


180 


185 


190 


195 


200 


205 


210 


215 


220 


225 


230 


235 


240 






0.46- 


-0.50 


155 


160 


165 


170 


175 


180 


185 


190 


195 


200 


205 


210 


215 


220 


225 


230 


235 


240 






0.51 - 


-0.55 


160 


165 


170 


175 


180 


185 


190 


195 


200 


205 


210 


215 


220 


225 


230 


235 


240 






0.56- 


-0.60 


165 


170 


175 


180 


185 


190 


195 


200 


205 


210 


215 


220 


225 


230 


235 


240 






0.61 - 


-0.65 


170 


175 


180 


185 


190 


195 


200 


205 


210 


215 


220 


225 


230 


235 


240 






0.66- 


-0.70 


175 


180 


185 


190 


195 


200 


205 


210 


215 


220 


225 


230 


235 


240 






0.71 - 


-0.75 


180 


185 


190 


195 


200 


205 


210 


215 


220 


225 


230 


235 


240 






0.76- 


-0.80 


185 


190 


195 


200 


205 


210 


215 


220 


225 


230 


235 


240 




\/AI \/P r.\ PARAMPP {nr\\ri\- 


0.81 - 


-0.85 


190 


195 


200 


205 


210 


215 


220 


225 


230 


235 


240 






0.86- 


-0.90 


195 


200 


205 


210 


215 


220 


225 


230 


235 


240 




U. IU~U. IUIIIIII 


0.91 - 


-0.95 


200 


205 


210 


215 


220 


225 


230 


235 


240 




txampie: insiaiiea is i /o 


0.96- 


- 1.00 


205 


210 


215 


220 


225 


230 


235 


240 




Measured clearance is 0.22 mm 


1.01 - 


- 1.05 


210 


215 


220 


225 


230 


235 


240 




Replace 175 pad with 185 pad 


1.06- 


- 1.10 


215 


220 


225 


230 


235 


240 




Pad number: (example) 


1.11 - 


- 1.15 


220 


225 


230 


235 


240 




Pad No. 175= 175 mm 


1.16- 


- 1.20 


225 


230 


235 


240 




PqH Mn 1«c; — 1 Q.R mm 


1.21 - 


- 1.25 


230 


235 


240 






1.26- 


- 1.30 


235 


240 






1.31 - 


- 1.35 


240 



















































EXHAUST 



MEASURED 
CLEARANCE 


INSTALLED PAD NUMBER 


120 


125 


130 


135 


140 


145 


150 


155 


160 


165 


170 


175 


180 


185 


190 


195 


200 


205 


210 


215 


220 


225 


230 


235 


240 


0.00- 


-0.04 










120 


125 


130 


135 


140 


145 


150 


155 


160 


165 


170 


175 


180 


185 


190 


195 


200 


205 


210 


215 


220 


0.05- 


-0.09 








120 


125 


130 


135 


140 


145 


150 


155 


160 


165 


170 


175 


180 


185 


190 


195 


200 


205 


210 


215 


220 


225 


0.10- 


-0.14 






120 


125 


130 


135 


140 


145 


150 


155 


160 


165 


170 


175 


180 


185 


190 


195 


200 


205 


210 


215 


220 


225 


230 


0.15- 


-0.19 




120 


125 


130 


135 


140 


145 


150 


155 


160 


165 


170 


175 


180 


185 


190 


195 


200 


205 


210 


215 


220 


225 


230 


235 


0.20- 


-0.25 


STANDARD CLEARANCE 


0.26- 


-0.30 


125 


130 


135 


140 


145 


150 


155 


160 


165 


170 


175 


180 


185 


190 


195 


200 


205 


210 


215 


220 


225 


230 


235 


240 




0.31 - 


-0.35 


130 


135 


140 


145 


150 


155 


160 


165 


170 


175 


180 


185 


190 


195 


200 


205 


210 


215 


220 


225 


230 


235 


240 






0.36- 


-0.40 


135 


140 


145 


150 


155 


160 


165 


170 


175 


180 


185 


190 


195 


200 


205 


210 


215 


220 


225 


230 


235 


240 






0.41 - 


-0.45 


140 


145 


150 


155 


160 


165 


170 


175 


180 


185 


190 


195 


200 


205 


210 


215 


220 


225 


230 


235 


240 






0.46- 


-0.50 


145 


150 


155 


160 


165 


170 


175 


180 


185 


190 


195 


200 


205 


210 


215 


220 


225 


230 


235 


240 






0.51 - 


-0.55 


150 


155 


160 


165 


170 


175 


180 


185 


190 


195 


200 


205 


210 


215 


220 


225 


230 


235 


240 






0.56- 


-0.60 


155 


160 


165 


170 


175 


180 


185 


190 


195 


200 


205 


210 


215 


220 


225 


230 


235 


240 






0.61 - 


-0.65 


160 


165 


170 


175 


180 


185 


190 


195 


200 


205 


210 


215 


220 


225 


230 


235 


240 






0.66- 


-0.70 


165 


170 


175 


180 


185 


190 


195 


200 


205 


210 


215 


220 


225 


230 


235 


240 






0.71 - 


-0.75 


170 


175 


180 


185 


190 


195 


200 


205 


210 


215 


220 


225 


230 


235 


240 






0.76- 


-0.80 


175 


180 


185 


190 


195 


200 


205 


210 


215 


220 


225 


230 


235 


240 






0.81 - 


-0.85 


180 


185 


190 


195 


200 


205 


210 


215 


220 


225 


230 


235 


240 






0.86- 


-0.90 


185 


190 


195 


200 


205 


210 


215 


220 


225 


230 


235 


240 






0.91 - 


-0.95 


190 


195 


200 


205 


210 


215 


220 


225 


230 


235 


240 




VALVE CLEARANCE (cold): 


0.96- 


- 1.00 


195 


200 


205 


210 


215 


220 


225 


230 


235 


240 




0.20 ~ 0.25 mm 


1.01 - 


- 1.05 


200 


205 


210 


215 


220 


225 


230 


235 


240 




Examole: Installed is 175 


1.06- 


- 1.10 


205 


210 


215 


220 


225 


230 


235 


240 




MopQiimH rlaarflnra iq 39 mm 


1.11 - 


- 1.15 


210 


215 


220 


225 


230 


235 


240 




Dn^UnA -\ ~7C k^oz-J i«#i+K 1QC k^o/-J 


1.16- 


- 1.20 


215 


220 


225 


230 


235 


240 




nc|jiaoc i / yj pau win i i uj |jau 


1.21 - 


- 1.25 


220 


225 


230 


235 


240 




raa numDer: ^example; 


1.26- 


- 1.30 


225 


230 


235 


240 




Pad No. 175 = 1.75 mm 


1.31 - 


- 1.35 


230 


235 


240 




Pad No. 185 = 1.85 mm 


1.36- 


- 1.40 


235 


240 






1.41 - 


- 1.45 


240 



















































3-23 



CHASSIS/BRAKE SYSTEM AIR BLEEDING 



INSP 
ADJ 



<& 



EC360000 

CHASSIS 

EC361012 

BRAKE SYSTEM AIR BLEEDING 




A WARNING 



Bleed the brake system if: 

• The system has been disassembled. 

• A brake hose has been loosened or 
removed. 

• The brake fluid is very low. 

• The brake operation is faulty. 

A dangerous loss of braking performance 
may occur if the brake system is not prop- 
erly bleed. 

1 . Remove: 

• Master cylinder cap 

• Diaphragm 

• Protector (rear brake) 

2. Bleed: 

• Brake fluid 
\M Front 

1] Rear 



Air bleeding steps: 

a. Add proper brake fluid to the reservoir. 

b. Install the diaphragm. Be careful not to 
spill any fluid or allow the reservoir to 
overflow. 

c. Connect the clear plastic tube ® tightly 
to the caliper bleed screw ©. 

d. Place the other end of the tube into a 
container. 

e. Slowly apply the brake lever or pedal 
several times. 

f. Pull the lever in or push down on the 
pedal. Hold the lever or pedal in position. 

g. Loosen the bleed screw and allow the 
lever or pedal to travel towards its limit. 

h. Tighten the bleed screw when the lever 
or pedal limit has been reached; then 
release the lever or pedal. 



Bleed screw: 
6 Nm (0.6 m • kg, 4.3 ft • lb) 



i. Repeat steps (e) to (h) until of the air 
bubbles have been removed from the 
system. 



3-24 



FRONT BRAKE ADJUSTMENT 



INSP 
ADJ 



<& 











(^\ i 


» 


Jk 


i^ 




<D 


®|L 


=S/t 


< ~ i 


r 


N| J 


, L 


j 




/ 






NOTE: 

If bleeding is difficult, it may be necessary to 
let the brake fluid system stabilize for a few 
hours. Repeat the bleeding procedure when 
the tiny bubbles in the system have disap- 
peared. 



j. Add brake fluid to the level line on the 
reservoir. 



A WARNING 



Check the operation of the brake after 
bleeding the brake system. 



3. Install: 

• Protector (rear brake) 

• Diaphragm 

• Master cylinder cap 



EC362040 

FRONT BRAKE ADJUSTMENT 

1. Check: 

• Brake lever position ® 




Brake lever position ® 



Standard position 



95 mm (3.74 in) 



Extent of adjustment 



76 ~ 97 mm 
(2.99 ~ 3.82 in) 



2. Remove: 

• Lever cover 

3. Adjust: 

• Brake lever position 



Brake lever position adjustment steps: 

• Loosen the locknut ©. 

• Turn the adjusting bolt © until the lever 
position ® is within specified position. 

• Tighten the locknut. 



Locknut: 
5 Nm (0.5 m • kg, 3.6 ft • lb) 



. . Ill 

Be sure to tighten the locknut, as it wil 
cause poor brake performance. 



4. Install: 

• Lever cover 



3-25 



REAR BRAKE ADJUSTMENT/ 
FRONT BRAKE PAD INSPECTION AND REPLACEMENT 



INSP 



ADJ 



<& 





W 



w 




(§^fc* 






EC364002 

REAR BRAKE ADJUSTMENT 

1. Check: 

• Brake pedal height @ 
Out of specification -^ Adjust. 




Brake pedal height © 
5 mm (0.20 in) 



2. Adjust: 

• Brake pedal height 



Pedal height adjustment steps: 

• Loosen the locknut ©. 

• Turn the adjusting nut © until the pedal 
height ® is within specified height. 

• Tighten the locknut. 



A WARNING 



• Adjust the pedal height between the 
maximum [a] and the minimum \E as 
shown. (In this adjustment the bolt © 
end © should protrude out of the 
threaded portion but not be less than 
2 mm (0.08 in) © away from the brake 
pedal ©). 

• After the pedal height adjustment, make 
sure that the rear brake does not drag. 



EC365080 

FRONT BRAKE PAD INSPECTION AND 
REPLACEMENT 

1. Inspect: 

• Brake pad thickness @ 
Out of specification -> Replace as a 
set. 



^ 


Brake pad thickness ©: 


Standard 


<Limit> 


4.4 mm (0.17 in) 


1.0 mm (0.04 in) 



2. Replace: 
• Brake pad 



Brake pad replacement steps: 

• Remove the pad pin plug ©. 



3-26 



FRONT BRAKE PAD INSPECTION AND REPLACEMENT 



INSP 
ADJ 



<& 







• Loosen the pad pin (2). 

• Remove the brake hose holder (5) and cal- 
iper from the front fork. 

• Remove the pad pin and brake pads (§). 

• Connect the transparent hose (§) to the 
bleed screw ® and place the suitable con- 
tainer under its end. 

• Loosen the bleed screw and push the cali- 
per piston in. 

CAUTION: 

Do not reuse the drained brake fluid. 

• Tighten the bleed screw. 



Bleed screw: 
6 Nm (0.6 m • kg, 4.3 ft • lb) 



• Install the brake pads ® and pad pin. 

NOTE: 

• Install the brake pads with their projec- 
tions ® into the caliper recesses ©■ 

• Temporarily tighten the pad pin at this 
point. 

• Install the brake hose holder (§) and cali- 
per ® and tighten the pad pin @. 

NOTE: 

Fit the brake hose holder cut © over the 
projection 0) on the front fork and clamp the 
brake hose. 



% 



Bolt (caliper): 

23Nm(2.3nrkg, 17fflb) 
Pad pin: 

18 Nm (1.8 nr kg, 13 ft* lb) 



3-27 



REAR BRAKE PAD INSPECTION AND REPLACEMENT 



INSP 
ADJ 



<& 




Install the pad pin plug 



% 



Pad pin plug: 
3 Nm (0.3 m • kg, 2.2 ft • lb) 



3. Inspect: 

• Brake fluid level 

Refer to "BRAKE FLUID LEVEL 
INSPECTION" section. 

4. Check: 

• Brake lever operation 

A softy or spongy feeling -> Bleed 
brake system. 

Refer to "BRAKE SYSTEM AIR 
BLEEDING" section. 






EC366060 

REAR BRAKE PAD INSPECTION AND 
REPLACEMENT 

1. Inspect: 

• Brake pad thickness ® 
Out of specification -^ Replace as a 
set. 



^ 


Brake pad thickness ®: 


Standard 


<Limit> 


6.4 mm (0.25 in) 


1.0 mm (0.04 in) 



2. Replace: 
• Brake pad 



Brake pad replacement steps: 

• Remove the protector © and pad pin plug 
©. 

• Loosen the pad pin ©. 

• Remove the rear wheel and caliper (§). 
Refer to "FRONT WHEEL AND REAR 
WHEEL" section in the CHAPTER 5. 



3-28 



REAR BRAKE PAD INSPECTION AND REPLACEMENT 



INSP 
ADJ 



<& 




• Remove the pad pin (J) and brake pads ®. 

• Connect the transparent hose ® to the 
bleed screw (§) and place the suitable con- 
tainer under its end. 

• Loosen the bleed screw and push the cali- 
per piston in. 



II! 

Do not reuse the drained brake fluid. 

• Tighten the bleed screw. 



^> 



Bleed screw: 
6 Nm (0.6 m • kg, 4.3 ft • lb) 



• Install the brake pad ® and pad pin (Q). 

NOTE: 

• Install the brake pads with their projec- 
tions ® into the caliper recesses ©. 

• Temporarily tighten the pad pin at this 
point. 

• Install the caliper © and rear wheel ©. 
Refer to "FRONT WHEEL AND REAR 
WHEEL" section in the CHAPTER 5. 

• Tighten the pad pin ©. 



Pad pin: 
18 Nm (1.8 nr kg, 13 ft •lb) 



Install the pad pin plug © and protector < 



Pad pin plug: 

3 Nm (0.3 m • kg, 2.2 ft • lb) 
Bolt (protector): 

7 Nm (0.7 m • kg, 5.1 ft • lb) 



3-29 



REAR BRAKE PAD INSULATOR INSPECTION/ 
BRAKE FLUID LEVEL INSPECTION 



INSP 



ADJ 



<& 





3. Inspect: 

• Brake fluid level 

Refer to "BRAKE FLUID LEVEL 
INSPECTION" section. 

4. Check: 

• Brake pedal operation 

A softy or spongy feeling -> Bleed 
brake system. 

Refer to "BRAKE SYSTEM AIR 
BLEEDING" section. 

EC36b000 

REAR BRAKE PAD INSULATOR 
INSPECTION 

1 . Remove: 

• Brake pad 

Refer to "REAR BRAKE PAD INSPEC- 
TION AND REPLACEMENT" section. 

2. Inspect: 

• Rear brake pad insulator © 
Damage -> Replace. 

EC367001 

BRAKE FLUID LEVEL INSPECTION 

1 . Place the master cylinder so that its top is 
in a horizontal position. 

2. Inspect: 

• Brake fluid level 

Fluid at lower level -» Fill up. 

® Lower level 

\M Front 
H Rear 



<Q 



Recommended brake fluid: 
DOT #4 



A WARNING 



• Use only designated quality brake fluid to 
avoid poor brake performance. 

• Refill with same type and brand of brake 
fluid; mixing fluids could result in poor 
brake performance. 

• Be sure that water or other contaminants 
do not enter master cylinder when refill- 
ing. 

• Clean up spilled fluid immediately to 
avoid erosion of painted surfaces or plas- 
tic parts. 



3-30 



SPROCKETS INSPECTION/DRIVE CHAIN INSPECTION 



INSP 
ADJ 



<& 





©(D©0 ©©©©®® 



^^^^^rf^rf mngn 



® 



12510206 




EC368000 

SPROCKETS INSPECTION 

1. Inspect: 

• Sprocket teeth ® 
Excessive wear -> Replace. 

NOTE: 

Replace the drive, driven sprockets and drive 
chain as a set. 



EC369002 

DRIVE CHAIN INSPECTION 

1 . Remove: 

• Master link clip 

• Joint © 

• Drive chain © 



Clean: 

• Drive chain 
Place it in kerosene, and brush off as 
much dirt as possible. Then remove the 
chain from the kerosene and dry the 
chain. 



3. Measure: 

• Drive chain length (10 links) ® 
Out of specification -^ Replace. 




Drive chain length (10 links): 
Limit: 152.5 mm (6.00 in) 



4. Check: 

• Drive chain stiffness ® 
Clean and oil the chain and hold as 
illustrated. 
Stiff -> Replace drive chain. 



3-31 



DRIVE CHAIN SLACK ADJUSTMENT 



INSP 
ADJ 



<& 




^ IJTsffl 






5. Install: 

• Drive chain © 

• Joint © 

• Master link clip © 



|£gj 



Be sure to install the master link clip to the 
direction as shown. 

© Turning direction 

6. Lubricate: 
• Drive chain 




Drive chain lubricant: 
SAE 10W-30 motor oil or suit- 
able chain lubricants 



DRIVE CHAIN SLACK ADJUSTMENT 

1. Elevate the rear wheel by placing the 
suitable stand under the engine. 

2. Check: 

• Drive chain slack © 
Above the seal guard installation bolt. 
Out of specification -^ Adjust. 




Drive chain slack: 
40 ~ 50 mm (1.6 ~ 2.0 in) 



NOTE: 

Before checking and/or adjusting, rotate the 
rear wheel through several revolutions and 
check the slack several times to find the tight- 
est point. Check and/or adjust chain slack with 
rear wheel in this "tight chain" position. 



3-32 



FRONT FORK INSPECTION 



INSP 
ADJ 



<& 




3. Adjust: 

• Drive chain slack 



Drive chain slack adjustment steps: 

• Loosen the axle nut © and locknuts ©. 

• Adjust chain slack by turning the adjusters 



To tighten -^ Turn adjuster © counter- 
clockwise. 
To loosen -> Turn adjuster © clockwise 
and push wheel forward. 



• Turn each adjuster exactly the same 
amount to maintain correct axle alignment. 
(There are marks ® on each side of chain 
puller alignment.) 

NOTE: 

Turn the adjuster so that the chain is in line 
with the sprocket, as viewed from the rear. 

CAi I: 



Too small chain slack will overload the 
engine and other vital parts; keep the 
slack within the specified limits. 

• Tighten the axle nut while pushing down 
the drive chain. 



Axle nut: 
125 Nm (12.5 m • kg, 90 ft • lb) 



•Tighten the locknuts. 



3i 



Locknut: 
16Nm(1.6m»kg, 11 ft* lb) 




EC36C000 

FRONT FORK INSPECTION 

1. Inspect: 

• Front fork smooth action 
Operate the front brake and stroke the 
front fork. 

Unsmooth action/oil leakage -> Repair 
or replace. 



3-33 



FRONT FORK OIL SEAL AND DUST SEAL CLEANING/ 

FRONT FORK INTERNAL PRESSURE RELIEVING/ 

FRONT FORK REBOUND DAMPING FORCE ADJUSTMENT 



INSP 



ADJ 



<a 






EC36D001 

FRONT FORK OIL SEAL AND DUST SEAL 
CLEANING 

1 . Remove: 

• Protector 

• Dust seal © 

NOTE: 

Use a thin screw driver, and be careful not to 
damage the inner fork tube and dust seal. 

2. Clean: 

• Dust seal ® 

• Oil seal © 

NOTE: 

• Clean the dust seal and oil seal after every 
run. 

• Apply the lithium soap base grease on the 
inner tube. 



FRONT FORK INTERNAL PRESSURE 
RELIEVING 

NOTE: 

If the front fork initial movement feels stiff during 
a run, relieve the front fork internal pressure. 

1 . Elevate the front wheel by placing a suit- 
able stand under the engine. 

2. Remove the air bleed screw © and 
release the internal pressure from the 
front fork. 

3. Install: 

• Air bleed screw 



1 Nm (0.1 m . kg, 0.7 ft ■ lb) 




EC36H002 

FRONT FORK REBOUND DAMPING FORCE 
ADJUSTMENT 

1. Adjust: 

• Rebound damping force 
By turning the adjuster ©. 



Stiffer (a) ^ Increase the rebound damp- 
ing force. (Turn the adjuster 
©in.) 

Softer © -^ Decrease the rebound damp- 
ing force. (Turn the adjuster 
©out.) 



3-34 



FRONT FORK COMPRESSION DAMPING FORCE 

ADJUSTMENT 



INSP 



ADJ 



<& 



^ 


Extent of adjustment: 


Maximum 


Minimum 


Fully turned in 
position 


20 clicks out (from 
maximum posi- 
tion) 



• STANDARD POSITION: 
This is the position which is back by the spe- 
cific number of clicks from the fully turned-in 
position. 




Standard position: 
10 clicks out 



II 

Do not force the adjuster past the minimum 
or maximum extent of adjustment. The 
adjuster may be damaged. 



A WARNING 



Always adjust each front fork to the same 
setting. Uneven adjustment can cause poor 
handling and loss of stability. 




EC36J001 

FRONT FORK COMPRESSION DAMPING 
FORCE ADJUSTMENT 

1 . Remove: 

• Rubber cap 

2. Adjust: 

• Compression damping force 
By turning the adjuster ©. 



Stiffer ® -^ Increase the compression 

damping force. (Turn the 

adjuster © in.) 
Softer © -^ Decrease the compression 

damping force. (Turn the 

adjuster © out.) 



3-35 



REAR SHOCK ABSORBER INSPECTION 



INSP 
ADJ 



<& 



^ 


Extent of adjustment: 


Maximum 


Minimum 


Fully turned in 
position 


20 clicks out 
(from maximum 
position) 



• STANDARD POSITION: 
This is the position which is back by the spe- 
cific number of clicks from the fully turned-in 
position. 




Standard position: 
12 clicks out 
* 9 clicks out 



For EUROPE 



Illiiill 



Do not force the adjuster past the minimum 
or maximum extent of adjustment. The 
adjuster may be damaged. 



A WARNING 



Always adjust each front fork to the same 
setting. Uneven adjustment can cause poor 
handling and loss of stability. 



3. 



Install: 

• Rubber cap 




EC36K000 

REAR SHOCK ABSORBER INSPECTION 

1. Inspect: 

• Swingarm smooth action 
Abnormal noise/unsmooth action -> 
Grease the pivoting points or repair the 
pivoting points. 
Damage/oil leakage -» Replace. 



3-36 



REAR SHOCK ABSORBER SPRING PRELOAD 

ADJUSTMENT 



INSP 



ADJ 



<& 





REAR SHOCK ABSORBER SPRING 
PRELOAD ADJUSTMENT 

1. Elevate the rear wheel by placing the 
suitable stand under the engine. 

2. Remove: 

• Rear frame 

3. Loosen: 

• Locknut © 

4. Adjust: 

• Spring preload 

By turning the adjuster ©. 



Stiffer — > Increase the spring preload. 

(Turn the adjuster © in.) 
Softer -> Decrease the spring preload. 

(Turn the adjuster © out.) 



^ 


Spring length (installed) ®: 


Standard length 


Extent of adjustment 


249 mm (9.80 in) 
*264 mm (10.39 in) 


240.5 ~ 258.5 mm 

(9.47 -10.18 in) 

*255.5 ~ 273.5 mm 

(10.06 -10.77 in) 



* For EUROPE 
NOTE: 



• Be sure to remove all dirt and mud from 
around the locknut and adjuster before 
adjustment. 

• The length of the spring (installed) changes 
1 .5 mm (0.06 in) per turn of the adjuster. 



ill 

Never attempt to turn the adjuster beyond 
the maximum or minimum setting. 

5. Tighten: 

• Locknut 

6. Install: 

• Rear frame (upper) 



32 Nm (3.2 m ■ kg, 23 ft ■ lb) 



Rear frame (lower) 



29 Nm (2.9 m • kg, 21 ft • lb) 



3-37 



REAR SHOCK ABSORBER REBOUND 
DAMPING FORCE ADJUSTMENT 



INSP 



ADJ 



<& 



EC36N014 

REAR SHOCK ABSORBER REBOUND 
DAMPING FORCE ADJUSTMENT 

1. Adjust: 

• Rebound damping force 
By turning the adjuster ©. 




Stiffer ® -^ Increase the rebound damp- 
ing force. (Turn the adjuster 
©in.) 

Softer © -» Decrease the rebound damp- 
ing force. (Turn the adjuster 
© out.) 



^ 


Extent of adjustment: 


Maximum 


Minimum 


Fully turned in 
position 


20 clicks out 
(from maximum 
position) 




• STANDARD POSITION: 
This is the position which is back by the spe- 
cific number of clicks from the fully turned-in 
position. (Which align the punch mark (a) on 
the adjuster with the punch mark © on the 
bracket.) 




Standard position: 
About 12 clicks out 
*About 13 clicks out 



For EUROPE 



M^MmE 



Do not force the adjuster past the minimum 
or maximum extent of adjustment. The 
adjuster may be damaged. 



3-38 



REAR SHOCK ABSORBER LOW COMPRESSION 
DAMPING FORCE ADJUSTMENT 



INSP 



ADJ 



<& 




EC36C000 

REAR SHOCK ABSORBER LOW 
COMPRESSION DAMPING FORCE 
ADJUSTMENT 

1. Adjust: 

• Low compression damping force 
By turning the adjuster ©. 



Stiffer ® -^ Increase the low compres- 
sion damping force. (Turn 
the adjuster © in.) 

Softer © -> Decrease the low compres- 
sion damping force. (Turn 
the adjuster © out.) 



^ 


Extent of adjustment: 


Maximum 


Minimum 


Fully turned in 
position 


20 clicks out 
(from maximum 
position) 




• STANDARD POSITION: 
This is the position which is back by the spe- 
cific number of clicks from the fully turned-in 
position. (Which align the punch mark (a) on 
the adjuster with the punch mark © on the 
high compression damping adjuster.) 




Standard position: 
About 12 clicks out 



2| 

Do not force the adjuster past the minimum 
or maximum extent of adjustment. The 
adjuster may be damaged. 



3-39 



REAR SHOCK ABSORBER HIGH COMPRESSION 
DAMPING FORCE ADJUSTMENT 



INSP 



ADJ 



<& 




EC36d000 

REAR SHOCK ABSORBER HIGH 
COMPRESSION DAMPING FORCE 
ADJUSTMENT 

1. Adjust: 

• High compression damping force 
By turning the adjuster ©. 



Stiffer ® -^ Increase the high compres- 
sion damping force. (Turn 
the adjuster © in.) 

Softer © -> Decrease the high compres- 
sion damping force. (Turn 
the adjuster © out.) 



^ 


Extent of adjustment: 


Maximum 


Minimum 


Fully turned in 
position 


2 turns out 
(from maximum 
position) 




• STANDARD POSITION: 
This is the position which is back by the spe- 
cific number of turns from the fully turned-in 
position. (Which align the punch mark ® on 
the adjuster with the punch mark © on the 
adjuster body.) 




Standard position: 
About 1-1/2 turns out 
*About 1 turn out 



For EUROPE 



M^MmE 



Do not force the adjuster past the minimum 
or maximum extent of adjustment. The 
adjuster may be damaged. 



3-40 



TIRE PRESSURE CHECK/SPOKES INSPECTION AND 

TIGHTENING/WHEEL INSPECTION 



INSP 



ADJ 



<& 




EC36Q000 

TIRE PRESSURE CHECK 

1. Measure: 
• Tire pressure 
Out of specification -^ Adjust. 




Standard tire pressure: 
100 kPa (1.0 kgf/cm 2 , 15 psi) 



NOTE: 

• Check the tire while it is cold. 

• Loose bead stoppers allow the tire to slip off 
its position on the rim when the tire pressure 
is low. 

• A tilted tire valve stem indicates that the tire 
slips off its position on the rim. 

• If the tire valve stem is found tilted, the tire is 
considered to be slipping off its position. Cor- 
rect the tire position. 




EC36S002 

SPOKES INSPECTION AND TIGHTENING 

1. Inspect: 

• Spokes © 
Bend/damage -^ Replace. 
Loose spoke -^ Retighten. 

2. Tighten: 

• Spokes |\|3Nm(0.3m.kg,2.2ft.lb)~ 



NOTE: 

Be sure to retighten these spokes before and 
after break-in. After a practice or a race check 
spokes for looseness. 




EC36T000 

WHEEL INSPECTION 

1. Inspect: 

• Wheel runout 
Elevate the wheel and turn it. 
Abnormal runout -^ Replace. 



3-41 



STEERING HEAD INSPECTION AND ADJUSTMENT 



INSP 
ADJ 



<& 





Inspect: 

• Bearing free play 
Exist play -^ Replace. 




STEERING HEAD INSPECTION AND 
ADJUSTMENT 

1 . Elevate the front wheel by placing a suit- 
able stand under the engine. 

2. Check: 

• Steering shaft 

Grasp the bottom of the forks and gen- 
tly rock the fork assembly back and 
forth. 
Free play -^ Adjust steering head. 

3. Check: 

• Steering smooth action 

Turn the handlebar lock to lock. 
Unsmooth action -^ Adjust steering ring 
nut. 




4. Adjust: 

• Steering ring nut 



Steering ring nut adjustment steps: 

• Remove the number plate. 

• Remove the handlebar and handle crown. 

• Loosen the ring nut © using the ring nut 
wrench ©. 



^ 



Ring nut wrench: 
YU-33975/90890-01403 



3-42 



STEERING HEAD INSPECTION AND ADJUSTMENT 



INSP 
ADJ 



<& 




© ®\Jj 


If 


[Z^>FWD 


f _^~^ 


a 



^ 



• Tighten the ring nut 
wrench 0. 

NOTE: 



using ring nut 



• Apply the lithium soap base grease on the 
thread of the steering shaft. 

• Set the torque wrench to the ring nut 
wrench so that they form a right angle. 



\ 



Ring nut wrench: 
YU-33975/90890-01403 



Ring nut (initial tightening): 
38 Nm (3.8 m • kg, 27 ft • lb) 



• Loosen the ring nut one turn. 

• Retighten the ring nut using the ring nut 



wrench. 



A WARNING 



Avoid over-tightening. 



Ring nut (final tightening): 
7 Nm (0.7 m • kg, 5.1 ft • lb) 



• Check the steering shaft by turning it lock 
to lock. If there is any binding, remove the 
steering shaft assembly and inspect the 
steering bearings. 

• Install the handle crown (§), plain washer, 
steering shaft nut (§), handlebar ®, han- 
dlebar holder ® and number plate (§). 

NOTE: 

• The upper handlebar holder should be 
installed with the punched mark ® for- 
ward. 

• Insert the end of fuel breather hose (jg) into 
the hole of the number plate. 

CAI M: 



First tighten the bolts on the front side of 
the handlebar holder, and then tighten 
the bolts on the rear side. 



^> 



Steering shaft nut: 

145 Nm (14.5 m • kg, 105 ft • lb) 
Handlebar upper holder: 

28 Nm (2.8 m • kg, 20 ft • lb) 
Pinch bolt (handle crown): 

23 Nm (2.3 m • kg, 17 ft • lb) 
Number plate: 

7 Nm (0.7 m • kg, 5.1 ft • lb) 



3-43 



LUBRICATION 



INSP 
ADJ 



<& 



LUBRICATION 

To ensure smooth operation of all compo- 
nents, lubricate your machine during setup, 
after break-in, and after every race. 
© All control cable 
© Clutch lever pivot 
© Shift pedal pivot 
© Footrest pivot 
© Throttle-to-handlebar contact 
© Drive chain 

® Tube guide cable winding portion 
© Throttle cable end 
© Clutch cable end 
® Hot starter cable end 



[a] Use Yamaha cable lube or equivalent on these 

areas. 
[H Use SAE 10W-30 motor oil or suitable chain 

lubricants. 
\c\ Lubricate the following areas with high quality, 

lightweight lithium-soap base grease. 

CAUTION: 



Wipe off any excess grease, and avoid get- 
ting grease on the brake discs. 






B 








3-44 



ELECTRICAL/SPARK PLUG INSPECTION 



INSP 
ADJ 



<& 




EC370000 

ELECTRICAL 

EC371001 

SPARK PLUG INSPECTION 

1 . Remove: 

• Spark plug 

2. Inspect: 

• Electrode © 
Wear/damage -> Replace. 

• Insulator color (2) 

Normal condition is a medium to light 
tan color. 

Distinctly different color -^ Check the 
engine condition. 

NOTE: 

When the engine runs for many hours at low 
speeds, the spark plug insulator will become 
sooty, even if the engine and carburetor are in 
good operating condition. 

3. Measure: 

• Plug gap ® 

Use a wire gauge or thickness gauge. 
Out of specification -> Regap. 




Spark plug gap: 
0.7 - 0.8 mm (0.028 ~ 0.031 in) 



4. Clean the plug with a spark plug cleaner 
if necessary. 




5. Tighten: 
• Spark plug 



13 Nm (1.3 m kg, 9.4 ft lb) 



NOTE: 

• Before installing a spark plug, clean the gas- 
ket surface and plug surface. 

• Finger-tighten ® the spark plug before 
torquing to specification ©. 



3-45 



IGNITION TIMING CHECK 



INSP 
ADJ 



<& 




IGNITION TIMING CHECK 

1 . Remove: 

• Timing plug © 



f, 



2. Attach: 

• Timing light 

• Inductive tachometer 
To the spark plug lead. 



Timing light: 

YM-33277-A/90890-031 41 
Inductive tachometer: 

YU-8036-B 
Engine tachometer: 

90890-03113 




Check: 

• Ignition timing 



Checking steps: 

• Start the engine and let it warm up. Let the 
engine run at the specified speed. 




Engine speed: 
1,900 ~ 2,100 r/min 



• Visually check the stationary pointer ® is 
within the firing range (b) on the rotor. 
Incorrect firing range -> Check rotor and 
pickup assembly. 



4. Install: 

• Timing plug 



3-46 



SEAT, FUEL TANK AND SIDE COVERS 



ENG 



% 



EC400000 

ENGINE 



EC4R0000 



SEAT, FUEL TANK AND SIDE COVERS 



$*& 



10 Nm (1.0 m -kg, 7.2 ft- lb) 




7 Nm (0.7 m - kg, 5.1 ft • lb) 



7 Nm (0.7 m - kg, 5.1 ft • lb) 



Extent of removal: 



© Seat removal 

® Side covers removal 



© Fuel tank removal 
© Number plate removal 



Extent of removal 


Order 


Part name 


Q'ty 


Remarks 


Preparation for removal 




SEAT, FUEL TANK AND SIDE 
COVERS REMOVAL 

Turn the fuel cock to "OFF". 
Disconnect the fuel hose. 






©I ' 


1 ©I 

D 

©1 


1 
2 
3 
4 
5 
6 
7 
8 


Seat 

Air scoop (left and right) 

Fitting band 

Bolt (fuel tank) 

Fuel tank 

Side cover (left) 

Side cover (right) 

Number plate 


1 
2 
1 
2 

1 
1 
1 
1 


Remove on fuel tank side. 



4-1 



SEAT, FUEL TANK AND SIDE COVERS 



ENG 



% 




REMOVAL POINTS 
Side cover 

1 . Remove: 

• Bolt (side cover) 

• Side cover (left) © 

• Side cover (right) ® 

NOTE: 



Draw the side cover downward to remove it 
because its claws ® are inserted in the air fil- 
ter case. 




4-2 



EXHAUST PIPE AND SILENCER 



ENG 



% 



EC4S0000 

EXHAUST PIPE AND SILENCER 




35 Nm (3.5 m • kg, 25 ft • lb) 




m 



20 Nm (2.0 m -kg, 14 ft- lb) 



10 Nm (1.0 m -kg, 7.2 ft -lb) 



13 Nm (1.3 m -kg, 9.4 ft -lb) 



\S\ Except for USA 
Extent of removal: 



© Silencer removal 



i Exhaust pipe removal 



Extent of removal 


Order 


Part name 


Q'ty 


Remarks 






EXHAUST PIPE AND 
SILENCER REMOVAL 






Preparation for removal 




Side cover (right) 




Refer to "SEAT, FUEL TANK AND SIDE 
COVERS" section. 


c 


) 


1 
2 
3 
4 
5 


Bolt (clamp) 

Bolt [silencer (front)] 

Bolt [silencer (rear)] 

Collar 

Silencer 




Only loosening. 




Q 


D 


6 
7 
8 
9 
10 


Clamp 

Nut (exhaust pipe) 

Bolt (exhaust pipe) 

Exhaust pipe 

Gasket 


2 





4-3 



EXHAUST PIPE AND SILENCER 



ENG 



% 




INSPECTION 

Exhaust pipe and silencer 

1. Inspect: 
• Gasket © 
Damage -^ Replace. 



ASSEMBLY AND INSTALLATION 
Exhaust pipe and silencer 

1. Install: 

• Gasket E^fl 

• Exhaust pipe © 

• Nut (exhaust pipe) © 



13 Nm (1.3 m kg, 9.4 ft lb) 



Bolt (exhaust pipe) © 



24 Nm (2.4 m kg, 17 ft lb) 



NOTE: 

First, temporarily tighten the nut (exhaust pipe), 
then tighten the bolt (exhaust pipe) 20 Nm 
(2.0 m • kg, 14 ft • lb). After that, retighten the 
nut (exhaust pipe) 1 3 Nm (1 .3 m • kg, 9.4 ft • lb) 
and then the bolt (exhaust pipe) 24 Nm 
(2.4 m* kg, 17 ft* lb). 




2. Install: 
• Clamp © 



20 Nm (2.0 m • kg, 14ft- lb) 



• Gasket © 

• Silencer© 

• Plain washer © 

• Bolt (silencer) © 



35 Nm (3.5 m ■ kg, 25 ft ■ lb) 



4-4 



RADIATOR 



ENG 



% 



EC450001 

RADIATOR 




10 Nm (1.0 m -kg, 7.2 ft- lb) 




10 Nm (1.0 m -kg, 7.2 ft -lb) 



34 Nm (3.4 m - kg, 24 ft - lb) 



Extent of removal: 




© Radiator removal 






Extent of removal 


Order 


Part name 


Q'ty 


Remarks 






RADIATOR REMOVAL 






Preparation for removal 




Drain the coolant. 
Seat and fuel tank 
Exhaust pipe 




Refer to "COOLANT REPLACEMENT" 

section in the CHAPTER 3. 

Refer to "SEAT, FUEL TANK AND SIDE 

COVERS" section. 

Refer to "EXHAUST PIPE AND 

SILENCER" section. 






1 


Engine guard 


1 








2 


Panel 


2 








3 


Clamp 


8 








4 


Radiator (right) 


1 








5 


Hose 2 


1 




c 


) 


6 


Hose 3 


1 




v 


7 


Hose 4 


1 








8 


Pipe 2/O-ring 


1/1 








9 


Radiator breather hose 


1 








10 


Radiator (left) 


1 








11 


Hose 1 


1 








12 


Pipe 1/O-ring 


1/1 





4-5 



RADIATOR 



ENG 



% 



EC456000 

HANDLING NOTE 



A WARNING 



Do not remove the radiator cap when the 
engine and radiator are hot. Scalding hot 
fluid and steam may be blown out under 
pressure, which could cause serious 
injury. 

When the engine has cooled, open the radi- 
ator cap by the following procedure: 
Place a thick rag, like a towel, over the radi- 
ator cap, slowly rotate the cap counter- 
clockwise to the detent. This procedure 
allows any residual pressure to escape. 
When the hissing sound has stopped, 
press down on the cap while turning coun- 
terclockwise and remove it. 




EC454000 

INSPECTION 

EC444100 

Radiator 

1. Inspect: 

• Radiator core © 
Obstruction -^ Blow out with com- 
pressed air through rear of the radiator. 
Bent fin -^ Repair/replace. 



EC455000 

ASSEMBLY AND INSTALLATION 



Radiator 

1. Install: 
• Pipe 1 © 



|\ 10 Nm (1.0 m 


- kg, 7.2 ft . lb) 


• Hose 1 © 


\ 2 Nm (0.2 m - 


kg, 1.4 ft- lb) 


• Pipe 2 © 


|Y 10 Nm (1.0 m 


• kg, 7.2 ft . lb) 


• Hose 3 © 


|Y 2Nm(0.2m. 


kg, 1.4 ft- lb) 


• Hose 4 © 


\ 2 Nm (0.2 m - 


kg, 1.4 ft- lb) 


2. Install: 
• Hose 2 © 


|Y 2Nm(0.2m. 


kg, 1.4 ft- lb) 


• Radiator (left) © 


|Y 10 Nm (1.0 m 


. kg, 7.2 ft . lb) 



4-6 



RADIATOR 



ENG 



% 






Install: 

• Radiator breather hose © 

• Radiator (right) © 



1"\ |10 Nm (1.0 m- kg, 7.2 ft • lb) 
Refer to "CABLE ROUTING DIA- 
GRAM" section in the CHAPTER 2. 



4. Install: 

• Panel © 

• Bolt (radiator panel upper) © 



10 Nm (1.0 m kg, 7.2 ft lb) 



NOTE: 

Fit the hook ® on the inner side first into the 
radiator. 



4-7 



CARBURETOR 



ENG 



% 



CARBURETOR 





3 Nm (0.3 m - kg, 2.2 ft - lb) 



3 Nm (0.3 m • kg, 2.2 ft - lb) 



Extent of removal: 




© Carburetor removal 






Extent of removal 


Order 


Part name 


Q'ty 


Remarks 






CARBURETOR REMOVAL 






Preparation for removal 




Fuel tank 




Refer to "SEAT, FUEL TANK AND SIDE 
COVERS" section. 






1 


Band 


1 








2 


TPS coupler 


1 








3 


Throttle cable cover 


1 








4 


Throttle cable 


2 




© 


5 


Clamp (air cleaner joint) 


1 


Loosen the screw (air cleaner joint). 






6 


Clamp (carburetor joint) 


2 


Loosen the screws (carburetor joint). 






7 


Hot starter plunger 


1 








8 


Carburetor 


1 




■ 




9 


Carburetor joint 


1 





4-8 



CARBURETOR 



ENG 



% 



CARBURETOR DISASSEMBLY 




Extent of removal: 




© Carburetor disassembly 






Extent of removal 


Order 


Part name 


Q'ty 


Remarks 






CARBURETOR DISASSEMBLY 










© 
© 
© 
© 
© 
© 


Breather hose 

Valve lever housing cover 

Screw (throttle shaft) 

Throttle valve 

Needle holder 

Jet needle 


4 




c 


) 


© 


Cover 






V. 


© 


Spring 










© 


Diaphragm (accelerator pump) 










® 


Float chamber 










® 


Pilot screw 




Refer to "REMOVAL POINTS". 






© 


Float pin 










© 


Float 










® 


Needle valve 







4-9 



CARBURETOR 



ENG 



% 




Extent of removal 


Order 


Part name 


Q'ty 


Remarks 






© 
© 
© 
© 


Main jet 
Needle jet 
Spacer 
Pilot jet 









) 


© 


Starter jet 






\. 


© 


Push rod 




Pull the push rod. 






® 


Throttle shaft assembly 










© 


Push rod link lever assembly 










© 


Pilot air jet 






• 




® 


Cold starter plunger 







4-10 



CARBURETOR 



ENG 



% 




EC466020 

HANDLING NOTE 



nniiii 



Do not loosen the screws {TPS (throttle 
position sensor)} © except when changing 
the TPS (throttle position sensor) due to 
failure because it will cause a drop in 
engine performance. 



REMOVAL POINTS 
Pilot screw 

1 . Remove: 

• Pilot screw © 

NOTE: 

To optimize the fuel flow at a small throttle 
opening, each machine's pilot screw has been 
individually set at the factory. Before removing 
the pilot screw, turn it in fully and count the 
number of turns. Record this number as the 
factory-set number of turns out. 




INSPECTION 
Carburetor 

1. Inspect: 

• Carburetor body 
Contamination -^ Clean. 

NOTE: 



• Use a petroleum based solvent for cleaning. 
Blow out all passages and jets with com- 
pressed air. 

• Never use a wire. 



4-11 



CARBURETOR 



ENG 



% 




2. Inspect: 

• Main jet © 

• Pilot jet ® 

• Needle jet (3) 

• Starter jet 

• Pilot air jet (§) 
Damage -^ Replace. 
Contamination -^ Clean. 

NOTE: 

• Use a petroleum based solvent for cleaning. 
Blow out all passages and jets with com- 
pressed air. 

• Never use a wire. 





f 


fl 


^ © 
4*P 








--© 






N> 


^ 


5 t 


r 



Needle valve 

1. Inspect: 

• Needle valve © 

• Valve seat ® 

Grooved wear ® -^ Replace. 
Dust © -> Clean. 




EC464300 

Throttle valve 

1. Check: 

• Free movement 
Stick -^ Repair or replace. 
Insert the throttle valve © into the car- 
buretor body, and check for free move- 
ment. 



Jet needle 

1. Inspect: 

• Jet needle © 
Bends/wear -^ Replace. 

• Clip groove 

Free play exists/wear -^ Replace. 

• Clip position 




Standard clip position: 
No.4 Groove 



4-12 



CARBURETOR 



ENG 



% 




EC46451 1 




Float height 

1. Measure: 

• Float height ® 
Out of specification -^ Adjust. 




Float height: 
8.0 mm (0.31 in) 



Measurement and adjustment steps: 

• Hold the carburetor in an upside down 
position. 

NOTE: 

• Slowly tilt the carburetor in the opposite 
direction, then take the measurement 
when the needle valve aligns with the float 
arm. 

• If the carburetor is level, the weight of the 
float will push in the needle valve, result- 
ing in an incorrect measurement. 

• Measure the distance between the mating 
surface of the float chamber and top of the 
float using a vernier calipers. 

NOTE: 

The float arm should be resting on the nee- 
dle valve, but not compressing the needle 
valve. 

• If the float height is not within specifica- 
tion, inspect the valve seat and needle 
valve. 

• If either is worn, replace them both. 

• If both are fine, adjust the float height by 
bending the float tab © on the float. 

• Recheck the float height. 



EC464600 

Float 

1. Inspect: 
• Float © 
Damage -^ Replace. 



4-13 



CARBURETOR 



ENG 



% 




Starter plunger 

1. Inspect: 

• Cold starter plunger © 

• Hot starter plunger © 
Wear/damage -^ Replace. 



Accelerator pump 

1. Inspect: 

• Diaphragm (accelerator pump) © 

• Spring © 

• Cover © 

• O-ring @ 

• Push rod © 

Tears (diaphragm)/damage -^ Replace. 
Dirt -^ Clean. 

2. Inspect: 

• Throttle shaft © 

• Spring © 

• Lever 1 © 

• Spring 1 © 

• Lever 2 © 

• Spring 2 © 
Dirt -^ Clean. 



ASSEMBLY AND INSTALLATION 
Carburetor 

1. Install: 

• Cold starter plunger © 



2. Install: 

• Pilot air jet © 



4-14 



CARBURETOR 



ENG 



% 




3. Install: 

• Spring 1 © 

• Lever 1 © 
To lever 2 (a 



NOTE: 

Make sure the spring 1 fits on the stopper ® of 
the lever 2. 



4. Install: 

• Spring 2 © 
To lever 2 (2 



5. Install: 

• Push rod link lever assembly © 

NOTE: 



Make sure the stopper ® of the spring 2 fits 
into the recess (b) in the carburetor. 



6. Install: 

• Plain washer © 



Circlip © 



7. Install: 
• Spring © 



To throttle shaft ©. 

NOTE: 

Install the bigger hook ® of the spring fits on 
the stopper © of the throttle shaft pulley. 



4-15 



CARBURETOR 



ENG 



% 




8. Install: 

• Throttle shaft assembly © 

• Plain washer (metal) © 

• Plain washer (resin) © 

• Valve lever © 

NOTE: 

• Apply the fluorochemical grease on the bear- 
ings. 

• Fit the projection © on the throttle shaft 
assembly into the slot © in the TPS (throttle 
position sensor). 

• Make sure the stopper © of the spring fits 
into the recess in the carburetor. 

• Turn the throttle shaft assembly left while 
holding down the lever 1 © and fit the throt- 
tle stop screw tip © to the stopper © of the 
throttle shaft assembly pulley. 



9. Install: 

• Push rod © 

NOTE: 



While holding down the lever 1 ©, insert the 
push rod farthest into the carburetor. 



10. Install: 

• Starter jet © 

• Pilot jet© 

• Spacer © 

• Needle jet © 

• Main jet © 



4-16 



CARBURETOR 



ENG 



% 




11. Install: 

• Needle valve © 

• Float © 

• Float pin ® 

NOTE: 

• After installing the needle valve to the float, 
install them to the carburetor. 

• Check the float for smooth movement. 

12. Install: 

• Pilot screw © 

• Spring © 

• Washer © 

• O-ring @ 



Note the following installation points: 

• Turn in the pilot screw until it is lightly 
seated. 

• Turn out the pilot screw by the number of 
turns recorded before removing. 




Pilot screw: 
2 turns out (example) 




13. Install: 

• O-ring 

• Float chamber © 

• Screw (float chamber) © 

• Cable holder (throttle stop screw cable) 

© 

• Hose holder (carburetor breather hose) 

© 

14. Install: 

• Diaphragm (accelerator pump) © 

• Spring © 

• O-ring © 

• Cover © 

• Hose holder (drain hose) © 

• Screw (cover) © 

NOTE: 

Install the diaphragm (accelerator pump) with 
its mark ® facing the spring. 



4-17 



CARBURETOR 



ENG 



% 




15. Install: 

• Jet needle © 

• Collar © 

• Spring © 

• Needle holder 

• Throttle valve plate © 
To throttle valve ©. 



16. Install: 

• Throttle valve assembly © 

• Screw (throttle shaft) © 



NOTE: 

Install the valve lever rollers © into the slits ® 
of the throttle valve. 



17. Install: 

• O-ring © 

• Valve lever housing cover © 

• Bolt (valve lever housing cover) 



18. Install: 

• Carburetor breather hose © 
Refer to "CABLE ROUTING DIA- 
GRAM" section in the CHAPTER 2. 



4-18 



CARBURETOR 



ENG 



% 




Accelerator pump timing adjustment 



Adjustment steps: 
NOTE: 



In order for the throttle valve height ® to 
achieve the specified value, tuck under the 
throttle valve plate © the rod © etc. with 
the same outer diameter as the specified 
value. 




Throttle valve height: 
3.40 mm (0.134 in) 



• Fully turn in the accelerator pump adjust- 
ing screw (3). 

• Check that the link lever has free play 
© by pushing lightly on it. 

• Gradually turn out the adjusting screw 
while moving the link lever until it has no 
more free play. 



Carburetor installation 

1. Install: 

• Carburetor joint © 



3 Nm (0.3 m • kg, 2.2 ft ■ lb) 



NOTE: 

Install the projection ® on the cylinder head 
between the carburetor joint slots ©. 



2. Install: 

• Carburetor © 

NOTE: 



Install the projection ® between the carburetor 
joint slots. 



Install: 

• Hot starter plunger © 



2 Nm (0.2 m kg, 1.4 ft lb) 



4-19 



CARBURETOR 



ENG 



% 




4. Tighten: 

• Screw (air cleaner joint) © 



3 Nm (0.3 m • kg, 2.2 ft • lb) 



Screw (carburetor joint) © 



3 Nm (0.3 m ■ kg, 2.2 ft • lb) 



5. Install: 

• Throttle cable © 

6. Adjust: 

• Throttle grip free play 

Refer to "THROTTLE CABLE ADJUST- 
MENT" section in the CHAPTER 3. 



7. Install: 

• Throttle cable cover © 

• Screw (throttle cable cover) 



4 Nm (0.4 m ■ kg, 2.9 ft ■ lb) 



8. Install: 

• TPS (throttle position sensor) coupler 

© 

• Clamp © 

Refer to "CABLE ROUTING DIA- 
GRAM" section in the CHAPTER 2. 



4-20 



CAMSHAFTS 



ENG 



% 



CAMSHAFTS 

CYLINDER HEAD COVER 




^ ^ 



55 Nm (5.5 m • kg, 40 ft • lb) 



55 Nm (5.5 m • kg, 40 ft • lb) 



1 3 Nm (1.3 m -kg, 9.4 ft -lb) 




Extent of removal: 




© Cylinder head cover removal 






Extent of removal 


Order 


Part name 


Q'ty 


Remarks 






CYLINDER HEAD COVER 










REMOVAL 






Preparation for removal 




Seat and fuel tank 
Carburetor 




Refer to "SEAT, FUEL TANK AND SIDE 

COVERS" section. 

Refer to "CARBURETOR" section. 






1 
2 
3 
4 


Spark plug 

Engine upper bracket (right) 
Engine upper bracket (left) 
Cylinder head breather hose 






© 


5 


Oil tank breather hose 










6 


Bolt (cylinder head cover) 


2 








7 


Cylinder head cover 










8 


Gasket 






■ 




9 


Timing chain guide (upper) 







4-21 



CAMSHAFTS 



ENG 



% 



CAMSHAFTS 



10 Nm (1.0 nr kg, 7.2 ft -lb) 6 



& 7 




10 Nm (1.0 m -kg, 7.2 ft »lb) 



7 Nm (0.7 m - kg, 5.1 ft • lb) 



Extent of removal: 




© Camshaft removal 






Extent of removal 


Order 


Part name 


Q'ty 


Remarks 






CAMSHAFTS REMOVAL 










1 
2 
3 
4 


Timing plug 
Straight plug 
Tensioner cap bolt 
Timing chain tensioner 






c 


) 


5 
6 


Gasket 

Bolt (camshaft cap) 


10 


- Refer to "REMOVAL POINTS". 






7 


Camshaft cap 


2 








8 


Clip 


2 








9 


Exhaust camshaft 


1 








10 


Intake camshaft 


1 





4-22 



CAMSHAFTS 



ENG 



% 




REMOVAL POINTS 
Camshaft 

1 . Remove: 

• Timing plug © 

• Straight plug © 

2. Align: 

• "I" mark 

With stationary pointer. 



Checking steps: 

• Turn the crankshaft counterclockwise with 
a wrench. 

• Align the "I" mark ® on the rotor with the 
stationary pointer © on the crankcase 
cover. When the "I" mark is aligned with 
the stationary pointer, the piston is at the 
Top Dead Center (T.D.C.). 

NOTE: 

• In order to be sure that the piston is at Top 
Dead Center, the punch mark © on the 
exhaust camshaft and the punch mark 0) 
on the intake camshaft must align with the 
cylinder head surface, as shown in the 
illustration. 

• If there is no clearance, rotate the crank- 
shaft counterclockwise one turn. 



3. Loosen: 

• Tensioner cap bolt © 

4. Remove: 

• Timing chain tensioner < 



5. Remove: 

• Bolt (camshaft cap) © 



• Camshaft caps ® 

NOTE: 

Remove the bolts (camshaft cap) in a criss- 
cross pattern, working from the outside in. 

WW'mMfM. 



The bolts (camshaft cap) must be removed 
evenly to prevent damage to the cylinder 
head, camshafts or camshaft caps. 



4-23 



CAMSHAFTS 



ENG 



% 




6. Remove: 

• Clips 

• Exhaust camshaft © 

• Intake camshaft ® 



NOTE: 

Attach a wire (3) to the timing chain to prevent 
it from falling into the crankcase. 



INSPECTION 
Camshaft 

1. Inspect: 

• Cam lobes 
Pitting/scratches/blue discoloration -^ 
Replace. 

2. Measure: 

• Cam lobes length ® and © 
Out of specification -^ Replace. 




Cam lobes length: 
Intake: 

® 31 .200 -31 .300 mm 
(1.2283 -1.2323 in) 
<Limit>: 31.100 mm 
(1.2244 in) 

© 22.550 - 22.650 mm 
(0.8878 -0.8917 in) 
<Limit>: 22.450 mm 
(0.8839 in) 
Exhaust: 

(a) 30.950 -31 .050 mm 
(1.2185 -1.2224 in) 
<Limit>: 30.850 mm 
(1.2146 in) 

© 22.494 - 22.594 mm 
(0.8856 - 0.8895 in) 
<Limit>: 22.394 mm 
(0.8817 in) 




11151402 



3. Measure: 

• Runout (camshaft) 



Out of specification -> Replace. 




Runout (camshaft): 
Less than 0.03 mm (0.0012 in) 



4-24 



CAMSHAFTS 



ENG 



% 



Measure: 

• Camshaft-to-cap clearance 
Out of specification -^ Measure cam- 
shaft journal diameter. 




Camshaft-to-cap clearance: 
0.020 ~ 0.054 mm 
(0.0008 ~ 0.0021 in) 
<Limit>: 0.08 mm (0.003 in) 




Measurement steps: 

• Install the camshaft onto the cylinder 
head. 

• Position a strip of Plastigauge® © onto the 
camshaft. 

• Install the circlip, dowel pins and camshaft 
caps. 



Bolt (camshaft cap): 
10 Nm (1.0 or kg, 7.2 ft • lb) 



NOTE: 

• Tighten the bolts (camshaft cap) in a criss- 
cross pattern from innermost to outer 
caps. 

• Do not turn the camshaft when measuring 
clearance with the Plastigauge®. 

• Remove the camshaft caps and measure 
the width of the Plastigauge® ©. 



5. Measure: 

• Camshaft journal diameter ® 
Out of specification -^ Replace the 
camshaft. 

Within specification -^ Replace cam- 
shaft case and camshaft caps as a set. 




Camshaft journal diameter: 
21 .967-21 .980 mm 
(0.8648 ~ 0.8654 in) 



Camshaft sprocket 

1. Inspect: 

• Camshaft sprocket © 
Wear/damage -^ Replace the camshaft 
assembly and timing chain as a set. 



4-25 



CAMSHAFTS 



ENG 



% 




Decompression system 

1. Check: 

• Decompression system 



Checking steps: 

• Check that the decompressor cam © 
moves smoothly. 

• Check that the decompressor lever pin (2) 
projects from the camshaft. 



Timing chain tensioner 

1. Check: 

• While pressing the tensioner rod lightly 
with fingers, use a thin screwdriver © 
and wind the tensioner rod up fully 
clockwise. 

• When releasing the screwdriver by 
pressing lightly with fingers, make sure 
that the tensioner rod will come out 
smoothly. 

• If not, replace the tensioner assembly. 



ASSEMBLY AND INSTALLATION 

1. Install: 

• Exhaust camshaft © 

• Intake camshaft ® 



Installation steps: 

• Turn the crankshaft counterclockwise until 
the "I" mark ® on the rotor is aligned with 
the stationary pointer © on the crankcase 
cover. 

NOTE: 

• Apply the molybdenum disulfide oil on the 
camshafts. 

• Apply the engine oil on the decompression 
system. 



4-26 



CAMSHAFTS 



ENG 



% 





• Fit the timing chain (3) onto both camshaft 
sprockets and install the camshafts on the 
cylinder head. 

NOTE: 

The camshafts should be installed onto the 
cylinder head so that the exhaust cam 
sprocket punch mark © and the intake cam 
sprocket punch mark 0) align with the sur- 
face of the cylinder head. 

CAUTION: 



Do not turn the crankshaft during the 
camshaft installation. Damage or 
improper valve timing will result. 

• Install the clips and camshaft caps 0. 



Bolt (camshaft cap): 
10 Nm (1.0 m* kg, 7.2 ft •lb) 



NOTE: 

• Apply the engine oil on the thread and con- 
tact surface of the bolts (camshaft cap) ©. 

• Tighten the bolts (camshaft cap) in a criss- 
cross pattern. 



MMmSmM 

The bolts (camshaft cap) must be tight- 
ened evenly, or damage to the cylinder 
head, camshaft caps, and camshaft will 
result. 




2. Install: 

• Timing chain tensioner 



Installation steps: 

• While pressing the tensioner rod lightly 
with fingers, use a thin screwdriver and 
wind the tensioner rod up fully clockwise. 



4-27 



CAMSHAFTS 



ENG 



% 




• With the rod fully wound and the chain 
tensioner UP mark ® facing upward, 
install the gasket © and the chain ten- 
sioner (2), and tighten the bolt (3) to the 
specified torque. 



Bolt (timing chain tensioner): 
10 Nm (1.0 m •kg, 7.2 ft • lb) 



• Release the screwdriver, check the ten- 
sioner rod to come out and tighten the 
gasket and the cap bolt (§) to the speci- 
fied torque. 



Tensioner cap bolt: 
7 Nm (0.7 m • kg, 5.1 ft • lb) 



Turn: 

• Crankshaft 
Counterclockwise several turns 

Check: 

• Rotor "I" mark 

Align with the crankcase stationary 
pointer. 

• Camshaft match marks 

Align with the cylinder head surface. 
Out of alignment -^ Adjust. 



4-28 



CYLINDER HEAD 



ENG 



% 



CYLINDER HEAD 

CYLINDER HEAD 




20 Nm (2.0 m -kg, 14 ft -lb) 




10 Nm (1.0 nr kg, 7.2 ft -lb) 



Extent of removal: 




© Cylinder head removal 






Extent of removal 


Order 


Part name 


Q'ty 


Remarks 






CYLINDER HEAD REMOVAL 






Preparation for removal 




Seat and fuel tank 

Exhaust pipe and silencer 

Radiator 

Carburetor 

Camshaft 




Refer to "SEAT, FUEL TANK AND SIDE 

COVERS" section. 

Refer to "EXHAUST PIPE AND 

SILENCER" section. 

Refer to "RADIATOR" section. 

Refer to "CARBURETOR" section. 

Refer to "CAMSHAFTS" section. 






1 


Oil delivery pipe 


1 








2 


Nut 


2 




© 


3* 


Bolt(L= 150 mm) 


2 


[ Refer to NOTE. 






4* 


Bolt (L= 160 mm) 


2 






5 


Cylinder head 


1 






6 


Gasket 


1 






7 


Dowel pin 


2 






8 


Timing chain guide (front) 


1 





NOTE: 

Tighten the cylinder head bolts to 30 Nm (3.0 m • kg, 22 ft • lb) in the proper tightening sequence, remove and 
retighten the cylinder head bolts to 20 Nm (2.0 m • kg, 14 ft • lb) in the proper tightening sequence, and then 
tighten the cylinder head bolts further to reach the specified angle 180° in the proper tightening sequence. 

4"~29 



CYLINDER HEAD 



ENG 



% 







zmBt 




Sis 


^ // , ^\y 




w* 


tr 



INSPECTION 
Cylinder head 

1. Eliminate: 

• Carbon deposits (from the combustion 
chambers) 

Use a rounded scraper. 

NOTE: 

Do not use a sharp instrument to avoid dam- 
aging or scratching: 

• Spark plug threads 

• Valve seats 

2. Inspect: 

• Cylinder head 
Scratches/damage -^ Replace. 




Measure: 

• Cylinder head warpage 



Out of specification -> Resurface. 




Cylinder head warpage: 
Less than 0.05 mm (0.002 in) 



Warpage measurement and resurface- 
ment steps: 

• Place a straightedge and a feeler gauge 
across the cylinder head. 

• Use a feeler gauge to measure the 
warpage. 

• If the warpage is out of specification, 
resurface the cylinder head. 

• Place a 400 ~ 600 grit wet sandpaper on 
the surface plate, and resurface the head 
using a figure-eight sanding pattern. 

NOTE: 

To ensure an even surface rotate the cylin- 
der head several times. 



4-30 



CYLINDER HEAD 



ENG 



% 




ASSEMBLY AND INSTALLATION 

1. Install: 

• Timing chain guide (front) © 

• Dowel pin © 

• Cylinder head gasket ® Q^Q 

• Cylinder head 

NOTE: 

While pulling up the timing chain, install the 
timing chain guide (front) and cylinder head. 

2. Install: 

• Plain washer © 

• Bolt [L=160 mm (6.30 in)] © 

• Bolt [L=150 mm (5.91 in)] © 




Installation steps: 



Tighten the cylinder head using the rota- 
tion angle procedure to obtain uniform 
tightening torque. 

• Wash the threads and contact surfaces of 
the bolts, the contact surfaces of the plain 
washers, the contact surface of the cylin- 
der head, and the threads of the crank- 
case. 

• Apply the molybdenum disulfide grease on 
the threads and contact surfaces of the 
bolts and on both contact surfaces of the 
plain washers. 

• Install the plain washers and bolts. 

• Tighten the bolts to the specified torque in 
two or three steps in the proper tightening 
sequence as shown. 




Bolts (cylinder head): 
1st: 
30 Nm (3.0 m • kg, 22 ft • lb) 



4-31 



CYLINDER HEAD 



ENG 



% 




• Remove the bolts. 

• Again apply the molybdenum disulfide 
grease on the threads and contact sur- 
faces of the bolts and on both contact sur- 
faces of the plain washers. 

• Retighten the bolts. 

NOTE: 

Tighten the bolts to the specified torque in 
two or three steps in the proper tightening 
sequence as shown. 




Bolts (cylinder head): 
2nd: 
20 Nm (2.0 m •kg, 14 ft* lb) 



• Put a mark on the corner © of the bolt 
(cylinder head) and the cylinder head ® 
as shown. 

NOTE: 

Tighten the bolts 90° in each of the two 
steps to reach the specified angle of 180° in 
the proper tightening sequence as shown. 



^> 



Bolts (cylinder head): 
Final: 
Specified angle 180° 



3. Install: 

• Nut (cylinder head) © 



10 Nm (1.0 m -kg, 7.2 ft -lb) 



4. Install: 

• Copper washer © 

• Oil delivery pipe ® 

• Union bolt (M8) ® 



18 Nm (1.8 m -kg, 13 ft -lb) 



Union bolt (M10)© 



20 Nm (2.0 m -kg, 14 ft -lb) 



4-32 



VALVES AND VALVE SPRINGS 



ENG 



% 



VALVES AND VALVE SPRINGS 

VALVES AND VALVE SPRINGS 





Extent of removal: 




© Valve removal 






Extent of removal 


Order 


Part name 


Q'ty 


Remarks 






VALVES AND VALVE SPRINGS 










REMOVAL 






Preparation for removal 




Cylinder head 




Refer to "CYLINDER HEAD" section. 






1 
2 
3 


Valve lifter 
Adjusting pad 
Valve cotter 


5 
5 
10 


Use special tool. 
" Refer to "REMOVAL POINTS". 






4 


Valve retainer 


5 




© 


5 


Valve spring 


5 








6 


Stem seal 


5 








7 


Valve spring seat 


5 








8 


Exhaust valve 


2 




■ 




9 


Intake valve 


3 





4-33 



VALVES AND VALVE SPRINGS 



ENG 



% 




REMOVAL POINTS 

1 . Remove: 

• Valve lifters © 

• Pads © 

NOTE: 



Identify each lifter © and pad © position very 
carefully so that they can be reinstalled in their 
original place. 



2. Check: 

• Valve sealing 
Leakage at the valve seat -> Inspect 
the valve face, valve seat and valve 
seat width. 



Checking steps: 

• Pour a clean solvent © into the intake and 
exhaust ports. 

• Check that the valve seals properly. 
There should be no leakage at the valve 
seat (2). 



3. Remove: 
• Valve cotters 

NOTE: 



Attach a valve spring compressor © between 
the valve spring retainer and the cylinder head 
to remove the valve cotters. 



^ 



Valve spring compressor: 
YM-401 9/90890-0401 9 



4-34 



VALVES AND VALVE SPRINGS 



ENG 



% 




INSPECTION 
Valve 

1. Measure: 

• Stem-to-guide clearance 



Stem-to-guide clearance = 
valve guide inside diameter ® - 
valve stem diameter © 



Out of specification 
valve guide. 



-^ Replace the 



/& 


Clearance (stem to guide): 


'A 


Intake: 


^^\ 


n m n n tvxi mm 


(0.0004 -0.0015 in) 


<Limit>: 0.08 mm (0.003 in) 


Exhaust: 


0.020 ~ 0.047 mm 


(0.0008 -0.0019 in) 


<Limit>: 0.10 mm (0.004 in) 



Replace: 
• Valve guide 



Replacement steps: 
NOTE: 



To ease guide removal, installation and to 
maintain correct fit heat the cylinder head in 
an over to 100 °C (212 °F). 

• Remove the valve guide using a valve 
guide remover ©. 

• Install the new valve guide using a valve 
guide remover © and valve guide installer 
©■ 

• After installing the valve guide, bore the 
valve guide using a valve guide reamer © 
to obtain proper stem-to-guide clearance. 



4-35 



VALVES AND VALVE SPRINGS 



ENG 



% 



^ 



Valve guide remover: 
Intake: 4.5 mm (0.18 in) 

YM-41 16/90890-041 16 
Exhaust: 5.0 mm (0.20 in) 

YM-4097/90890-04097 
Valve guide installer: 
Intake: 

YM-41 17/90890-041 17 
Exhaust: 

YM-4098/90890-04098 
Valve guide reamer: 
Intake: 4.5 mm (0.18 in) 

YM-41 18/90890-041 18 
Exhaust: 5.0 mm (0.20 in) 

YM-4099/90890-04099 



NOTE: 

After replacing the valve guide reface the 
valve seat. 



Inspect: 

• Valve face 

Pitting/wear -^ Grind the face. 

• Valve stem end 

Mushroom shape or diameter larger 
than the body of the stem -^ Replace. 




4. Measure: 

• Margin thickness ® 
Out of specification -^ Replace. 



^ 


Margin thickness: 
Intake: 

1.0 mm (0.039 in) 

<Limit>: 0.85 mm (0.033 in) 
Exhaust: 

1.0 mm (0.039 in) 

<Limit>: 0.85 mm (0.033 in) 





4-36 



VALVES AND VALVE SPRINGS 



ENG 



% 



; 


V 




& 






so- 




"J 

I 


I 


//////////////////// 11172103 



5. Measure: 

• Runout (valve stem) 
Out of specification -^ Replace. 




Runout limit: 
0.01 mm (0.0004 in) 



NOTE: 

• When installing a new valve always replace 
the guide. 

• If the valve is removed or replaced always 
replace the oil seal. 

6. Eliminate: 

• Carbon deposits 

(from the valve face and valve seat) 

7. Inspect: 

• Valve seats 

Pitting/wear -^ Reface the valve seat. 




8. Measure: 

• Valve seat width ® 
Out of specification -> Reface the valve 
seat. 




Valve seat width: 

Intake: 
0.9 ~ 1.1 mm (0.0354 - 0.0433 in) 
<Limit>: 1.6 mm (0.0630 in) 

Exhaust: 
0.9 - 1.1 mm (0.0354 - 0.0433 in) 
<Limit>: 1.6 mm (0.0630 in) 



Measurement steps: 

• Apply Mechanic's blueing dye (Dykem) © 
to the valve face. 

• Install the valve into the cylinder head. 

• Press the valve through the valve guide 
and onto the valve seat to make a clear 
pattern. 

• Measure the valve seat width. Where the 
valve seat and valve face made contact, 
blueing will have been removed. 

• If the valve seat is too wide, too narrow, or 
the seat is not centered, the valve seat 
must be refaced. 



4-37 



VALVES AND VALVE SPRINGS 



ENG 



% 




E)n — __ 


1 

h 




9. Lap: 

• Valve face 

• Valve seat 

NOTE: 

After refacing the valve seat or replacing the 
valve and valve guide, the valve seat and 
valve face should be lapped. 



Lapping steps: 

• Apply a coarse lapping compound to the 
valve face. 

CAUTION: 



Do not let the compound enter the gap 
between the valve stem and the guide. 

• Apply molybdenum disulfide oil to the 
valve stem. 

• Install the valve into the cylinder head. 

• Turn the valve until the valve face and 
valve seat are evenly polished, then clean 
off all of the compound. 

NOTE: 

For best lapping results, lightly tap the valve 
seat while rotating the valve back and forth 
between your hands. 

• Apply a fine lapping compound to the 
valve face and repeat the above steps. 

NOTE: 

After every lapping operation be sure to 
clean off all of the compound from the valve 
face and valve seat. 

• Apply Mechanic's blueing dye (Dykem) to 
the valve face. 

• Install the valve into the cylinder head. 

• Press the valve through the valve guide 
and onto the valve seat to make a clear 
pattern. 

• Measure the valve seat width again. If the 
valve seat width is out of specification, 
reface and relap the valve seat. 



4-38 



VALVES AND VALVE SPRINGS 



ENG 



% 




Valve spring 

1. Measure: 

• Valve spring free length ® 
Out of specification -^ Replace. 




Free length (valve spring): 
Intake: 

37.03 mm (1.46 in) 

<Limit>: 35.17 mm (1.38 in) 
Exhaust: 

37.68 mm (1.48 in) 

<Limit>: 35.79 mm (1.41 in) 



2. Measure: 

• Compressed spring force ® 
Out of specification -^ Replace. 
Installed length 




Compressed spring force: 

Intake: 
111.3-127.9 Nat 27.87 mm 
(11.3 -13.0 kg at 27.87 mm, 
24.91 -28.66 lb at 1.10 in) 

Exhaust: 
127.4 -146.4 Nat 27.38 mm 
(13.0 - 14.9 kg at 27.38 mm, 
28.66 -32.85 lb at 1.08 in) 





^ r^\ 








AS^ 








y W0MMWm, n.™ 




3. Measure: 
• Spring tilt (a) 
Out of specification -^ Replace. 




Spring tilt limit: 
Intake: 

2.571.61 mm (0.063 in) 
Exhaust: 

2.571 .65 mm (0.065 in) 



Valve lifter 

1. Inspect: 
• Valve lifter 
Scratches/damage -> Replace both lift- 
ers and cylinder head. 



4-39 



VALVES AND VALVE SPRINGS 



ENG 



% 




Combination of cylinder head and valve 
lifter 

1. Combination: 

For this combination, match the paint 
color on the cylinder head with that on the 
valve lifter according to the chart below. 



Combination 


Cylinder head mark 
© (color) 


Valve lifter mark 
© (color) 


Blue 


Blue 


Yellow 


Yellow 


Purple 


Black 



NOTE: 

When you purchase a cylinder head, you can- 
not designate its size. Choose the valve lifter 
that matches the above chart. 



ASSEMBLY AND INSTALLATION 

1. Apply: 

• Molybdenum disulfide oil 
Onto the valve stem and valve stem 
seal. 




2. Install: 

• Valves © 

• Valve spring seats © 

• Valve stem seals © EB3 

• Valve springs © 

• Valve spring retainers ® 



NOTE: 

• Make sure that each valve is installed in its 
original place, also referring to the painted 
color as follows. 

Intake (middle) @: blue 
Intake (right/left) ©: gray 
Exhaust: not paint 

• Install the valve springs with the larger pitch 
©facing upward. 

® Smaller pitch 



4-40 



VALVES AND VALVE SPRINGS 



ENG 



% 




*^\3 


/ ^v \l 






j^ === }^Uj 


^s>® ^ =s=== ===j^^ 5s::: ^XhK>^ 


■—Joj j 


©A^T ^> 


3&~ h^\ 




3. Install: 

• Valve cotters 

NOTE: 



While compressing the valve spring with a 
valve spring compressor © install the valve 
cotters. 



/- 



Valve spring compressor: 
YM-401 9/90890-0401 9 



4. To secure the valve cotters onto the 
valve stem, lightly tap the valve tip with a 
piece of wood. 

CAUTION: 



Hitting the valve tip with excessive force 
could damage the valve. 



5. Install: 

• Adjusting pad © 

• Valve lifter © 

NOTE: 

• Apply the engine oil on the valve lifters. 

• Apply the molybdenum disulfide oil on the 
valve stem end. 

• Valve lifter must turn smoothly when rotated 
with a finger. 

• Be careful to reinstall valve lifters and pads 
in their original place. 



4-41 



CYLINDER AND PISTON 



ENG 



% 



CYLINDER AND PISTON 

CYLINDER AND PISTON 





Extent of removal: 






© Cylinder removal 




© Piston removal 


Extent of removal 


Order 


Part name 


Q'ty 


Remarks 






CYLINDER AND PISTON 
REMOVAL 






Preparation for removal 




Cylinder head 




Refer to "CYLINDER HEAD" section. 


* 




1 
2 
3 


Bolt (cylinder) 

Cylinder 

Gasket 


1 
1 
1 








4 


Dowel pin 


2 




Q 


b 


5 
6 


Dowel pin/O-ring 
Piston pin clip 


1/1 
2 








7 
8 


Piston pin 
Piston 


1 
1 


Use special tool. 
" Refer to "REMOVAL POINTS". 






9 


Piston ring set 


1 





4-42 



CYLINDER AND PISTON 



ENG 



% 




REMOVAL POINTS 
Piston 

1 . Remove: 

• Piston pin clips © 

• Piston pin © 

• Piston © 

NOTE: 



• Put identification marks on each piston head 
for reference during reinstallation. 

• Before removing each piston pin, deburr the 
clip groove and pin hole area. If the piston 
pin groove is deburred and the piston pin is 
still difficult to remove, use the piston pin 
puller 0. 




Piston pin puller: 
YU-1 304/90890-01 304 



Do not use a hammer to drive the piston 
pin out. 

Piston ring 

1 . Remove: 
• Piston rings 

NOTE: 

Spread the end gaps apart while at the same 
time lifting the piston ring over the top of the 
piston crown, as shown in the illustration. 











-2§ : 












11210102 



INSPECTION 
Cylinder and piston 

1. Inspect: 

• Cylinder and piston walls 

Vertical scratches -^ Replace cylinder 
and piston. 

2. Measure: 

• Piston-to-cylinder clearance 



Measurement steps: 
1st step: 

• Measure the cylinder bore "C" with a cylin- 
der bore gauge. 

NOTE: 

Measure the cylinder bore "C" in parallel to 
and at right angles to the crankshaft. Then, 
find the average of the measurements. 



4-43 



CYLINDER AND PISTON 



ENG 



% 




Cylinder bore "C" 



Taper limit "T" 



Out of round "R" 



95.00 ~ 95.01 mm 
(3.7402 ~ 3.7406 in) 



0.05 mm (0.002 in) 



0.05 mm (0.002 in) 



'C" = Maximum D 



T" = (Maximum Di or D 2 ) 

- (Maximum Ds or De) 



'R" = (Maximum Di, D 3 or D 5 ) 

- (Minimum D2, Da or De) 



• If out of specification, replace the cylinder, 
and replace the piston and piston rings as 
set. 



2nd step: 

• Measure the piston skirt diameter "P" with 

a micrometer. 
® 8 mm (0.315 in) from the piston bottom edge 



Standard 



Piston size "P" 



94.945 -94.960 mm 
(3.738 ~ 3.739 in) 



• If out of specification, replace the piston 
and piston rings as a set. 

3rd step: 

• Calculate the piston-to-cylinder clearance 
with following formula: 



Piston-to-cylinder clearance = 
Cylinder bore "C" - 
Piston skirt diameter "P" 




Piston-to-cylinder clearance: 
0.040 ~ 0.065 mm 
(0.0016 -0.0026 in) 
<Limit>: 0.1 mm (0.004 in) 



• If out of specification, replace the cylinder, 
and replace the piston and piston rings as 
set. 



4-44 



CYLINDER AND PISTON 



ENG 



% 






f 


jy 


fb 






J^^Y\ 




:® 






11221401 



Piston ring 



1. Measure: 

• Ring side clearance 



Use a feeler gauge ©. 
Out of specification -^ Replace the pis- 
ton and rings as a set. 

NOTE: 

Clean carbon from the piston ring grooves and 
rings before measuring the side clearance. 



^ 




Side clearance: 


Standard 


<Limit> 


Top ring 


0.030 ~ 0.065 mm 
(0.0012 -0.0026 in) 


0.12 mm 
(0.005 in) 


2nd ring 


0.020 ~ 0.055 mm 
(0.0008 ~ 0.0022 in) 


0.12 mm 
(0.005 in) 



2. Position: 
• Piston ring 
(in cylinder) 

NOTE: 

Insert a ring into the cylinder and push it 
approximately 10 mm (0.39 in) into the cylin- 
der. Push the ring with the piston crown so that 
the ring will be at a right angle to the cylinder 
bore. 



(a) 10 mm (0.39 in) 

3. Measure: 
• Ring end gap 
Out of specification -^ Replace. 

NOTE: 

You cannot measure the end gap on the 
expander spacer of the oil control ring. If the oil 
control ring rails show excessive gap, replace 
all three rings. 



^ 




End gap: 


Standard 


<Limit> 


Top ring 


0.20 ~ 0.30 mm 
(0.008 -0.012 in) 


0.55 mm 
(0.022 in) 


2nd ring 


0.35 ~ 0.50 mm 
(0.014 -0.020 in) 


0.85 mm 
(0.033 in) 


Oil ring 


0.20 - 0.50 mm 
(0.01 - 0.02 in) 


— 



4-45 



CYLINDER AND PISTON 



ENG 



% 



Piston pin 

1. Inspect: 

• Piston pin 

Blue discoloration/grooves -^ Replace, 
then inspect the lubrication system. 

2. Measure: 

• Piston pin-to-piston clearance 



/\ 
















fr^jl / 


























xt~ 








^5S^ 









Measurement steps: 

• Measure the outside diameter (piston pin) 

®. 

If out of specification, replace the piston 

pin. 



Outside diameter (piston pin): 
17.991 -18.000 mm 
(0.7083 ~ 0.7087 in) 



Measure the inside diameter (piston) ©. 




Inside diameter (piston): 
18.004 -18.015 mm 
(0.7088 - 0.7093 in) 



• Calculate the piston pin-to-piston clear- 
ance with the following formula. 



Piston pin-to-piston clearance = 
Inside diameter (piston) © - 
Outside diameter (piston pin) ® 



If out of specification, replace the piston. 




Piston pin-to-piston clearance: 
0.004 - 0.024 mm 
(0.00016 -0.00094 in) 
<Limit>: 0.07 mm (0.003 in) 




ASSEMBLY AND INSTALLATION 
Piston 

1. Install: 

• Piston rings 
Onto the piston. 

NOTE: 



• Be sure to install the piston rings so that the 
manufacturer's marks or numbers are 
located on the upper side of the rings. 

• Lubricate the piston and piston rings liberally 
with engine oil. 



4-46 



CYLINDER AND PISTON 



ENG 



% 




as 



2. Position: 

• Top ring 

• 2nd ring 

• Oil ring 
Offset the piston ring end gaps 
shown. 

® Top ring end 

© 2nd ring end 

© Oil ring end (upper) 

@) Oil ring 

® Oil ring end (lower) 

3. Install: 

• Piston © 

• Piston pin © 

• Piston pin clips © 

NOTE: 

• Apply engine oil onto the piston pin and pis- 
ton. 

• Be sure that the arrow mark ® on the piston 
points to the exhaust side of the engine. 

• Before installing the piston pin clip, cover the 
crankcase with a clean rag to prevent the 
piston pin clip from falling into the crankcase. 

• Install the piston pin clips with their ends fac- 
ing downward. 



4. 



Lubricate: 

• Piston 

• Piston rings 



Cylinder 



NOTE: 



Apply a liberal coating of engine oil. 
Cylinder 



1. Install: 

• Dowel pins 

• O-ring 

• Gasket © EE3 

• Cylinder © 



NOTE: 

Install the cylinder with one hand while com- 
pressing the piston rings with the other hand. 



CA M: 

• Pass the timing chain © through the tim- 
ing chain cavity. 

• Be careful not to damage the timing chain 
guide © during installation. 

2. Install: 

• Bolt (cylinder) 



10 Nm (1.0 m kg, 7.2 ft lb) 



4-47 



CLUTCH 



ENG 



% 



CLUTCH 

CLUTCH 




10 Nm (1.0 m -kg, 7.2 ft -lb) 




75 Nm (7.5 m - kg, 54 ft - lb) 



Extent of removal: 



© Push rod and push lever removal © Push pod 1 disassembly 

® Friction plate and clutch plate removal ® Clutch housing removal 



Extent of removal 


Order 


Part name 


Q'ty 


Remarks 






CLUTCH REMOVAL 






Preparation for removal 




Drain the engine oil. 

Brake pedal 
Clutch cable 




Refer to "ENGINE OIL REPLACEMENT" 
section in the CHAPTER 3. 
Refer to "ENGINE REMOVAL" section. 
Disconnect at engine side. 












1 
2 


Clutch cover 
Gasket 


1 
1 




c 


) 




D Q 


) 


3 
4 
5 
6 


Dowel pin 
Clutch spring 
Pressure plate 
Push rod 1 


2 
6 

1 
1 








7 


Circlip 


1 








8 


Plain washer 


1 




(f) 




9 
10 


Bearing 
Ball 


1 
1 






11 


Push rod 2 


1 





4-48 



CLUTCH 



ENG 



% 



10 Nm (1.0 m -kg, 7.2 ft -lb) 




75 Nm (7.5 m - kg, 54 ft - lb) 



Extent of removal 


Order 


Part name 


Q'ty 


Remarks 








12 
13 


Clutch plate 
Friction plate 


8 
9 




a 




) 


14 
15 
16 


Nut 

Look washer 

Clutch boss 




Use special tool. 
" Refer to "REMOVAL POINTS". 






17 


Thrust washer 










18 


Clutch housing 






©I 


19 


Push lever 







4-49 



CLUTCH 



ENG 



% 




EC493000 

REMOVAL POINTS 

EC483211 

Clutch boss 

1 . Remove: 

• Nut© 

• Lock washer © 

• Clutch boss © 

NOTE: 

Straighten the lock washer tab and use the 
clutch holding tool to hold the clutch boss. 



^ 



Clutch holding tool: 
YM-91 042/90890-04086 



S For USA and CDN 

1] Except for USA and CDN 



EC494000 

INSPECTION 

EC484100 

Clutch housing and boss 

1. Inspect: 

• Clutch housing © 
Cracks/wear/damage -^ Replace. 

• Clutch boss © 
Scoring/wear/damage -> Replace. 



EC484201 

Primary driven gear 

1. Check: 

• Circumferential play 

Free play exists -> Replace. 

• Gear teeth ® 
Wear/damage -^ Replace. 



EC484400 

Clutch spring 

1. Measure: 

• Clutch spring free length ® 
Out of specification -^ Replace springs 
as a set. 



^ 


Clutch spring free length: 


Standard 


<Limit> 


50 mm (1.97 in) 


49 mm (1.93 in) 



4-50 



CLUTCH 



ENG 



% 



^V *v/ 




11411101 



EC484500 

Friction plate 

1. Measure: 

• Friction plate thickness 
Out of specification -> Replace friction 
plate as a set. 
Measure at all four points. 





Friction plate thickness: 
2.92 ~ 3.08 mm 
(0.115-0.121 in) 
<Limit>: 2.8 mm (0.110 in) 



EC484600 

Clutch plate 

1. Measure: 

• Clutch plate warpage 
Out of specification -^ Replace clutch 
plate as a set. 

Use a surface plate © and thickness 
gauge ©. 




Warp limit: 
0.1 mm (0.004 in) 




Push lever 

1. Inspect: 

• Push lever © 
Wear/damage -^ Replace. 



EC484810 

Push rod 

1. Inspect: 

• Push rod 1 © 

• Bearing © 

• Plain washer ® 

• Push rod 2 © 

• Ball © 
Wear/damage/bend -^ Replace. 



4-51 



CLUTCH 



ENG 



% 




EC4A5000 

ASSEMBLY AND INSTALLATION 
Push lever 

1. Install: 

• Push lever © 

• Bolt (push lever) 



10 Nm (1.0 m kg, 7.2 ft lb) 



NOTE: 

• Apply the lithium soap base grease on the oil 
seal lip. 

• Apply the engine oil on the push lever. 

• Fit the seat plate © in the groove ® of the 
push lever and tighten the bolt (seat plate). 




Clutch 

1. Install: 

• Primary driven gear © 

• Thrust washer © 

• Clutch boss © 

NOTE: 



Apply the engine oil on the primary driven gear 
inner circumference. 



2. Install: 

• Lock washer © Q^Q 

• Nut (clutch boss) © 



75 Nm (7.5 m • kg, 54 ft • lb) 



NOTE: 

Use the clutch holding tool © to hold the clutch 
boss. 



/- 



Clutch holding tool: 
YM-91 042/90890-04086 



\M For USA and CDN 

1] Except for USA and CDN 



4-52 



CLUTCH 



ENG 



% 




3. Bend the lock washer © tab. 



4. Install: 

• Friction plate © 

• Clutch plate © 

NOTE: 

• Install the clutch plates and friction plates 
alternately on the clutch boss, starting with a 
friction plate and ending with a friction plate. 

• Apply the engine oil on the friction plates and 
clutch plates. 




5. Install: 

• Bearing © 

• Plain washer © 

• Circlip © EB3 
To push rod 1 @. 

NOTE: 

Apply the engine oil on the bearing and plain 
washer. 



6. Install: 

• Push rod 2 © 

• Ball © 

• Push rod 1 ® 

NOTE: 

Apply the engine oil on the push rod 1, 2 and 
ball. 



4-53 



CLUTCH 



ENG 



% 




7. Install: 

• Pressure plate © 



8. Install: 

• Clutch spring 



Bolt (clutch spring) 



8 Nm (0.8 m ■ kg, 5.8 ft • lb) 



NOTE: 

Tighten the bolts in stage, using a crisscross 
pattern. 



9. Install: 

• Gasket (clutch cover) © 



• Dowel pin 



10. Install: 

• Clutch cover © 

• Bolt (clutch cover) 



10 Nm (1.0 m kg, 7.2 ft lb) 



NOTE: 

Tighten the bolts in stage, using a crisscross 
pattern. 



4-54 



OIL FILTER, WATER PUMP AND CRANKCASE COVER 

(RIGHT) 



ENG 



% 



OIL FILTER, WATER PUMP AND CRANKCASE COVER (RIGHT) 

OIL FILTER, WATER PUMP AND CRANKCASE COVER (RIGHT) 



$fe> 



20 Nm (2.0 m -kg, 14 ft -lb) 




15 11 IX1 10 Nm (1.0 m -kg, 7.2 ft- lb) 



10 Nm (1.0 m -kg, 7.2 ft -lb) 



14 Nm (1.4 m -kg, 10 ft -lb) 



Extent of removal: 






© Oil filter removal 

© Crankcase cover (right) removal 


© Water pump removal 


Extent of removal 


Order 


Part name 


Q'ty 


Remarks 


Preparation for removal 




OIL FILTER, WATER PUMP 
AND CRANKCASE COVER 
(RIGHT) REMOVAL 

Drain the engine oil. 

Drain the coolant. 

Exhaust pipe 

Brake pedal 
Clutch cover 




Refer to "ENGINE OIL REPLACEMENT" 

section in the CHAPTER 3. 

Refer to "COOLANT REPLACEMENT" 

section in the CHAPTER 3. 

Refer to "EXHAUST PIPE AND 

SILENCER" section. 

Refer to "ENGINE REMOVAL" section. 

Refer to "CLUTCH" section. 


& i 




1 


Oil filter cover 


1 






2 


Oil filter 


1 




a 


D 


D 


3 
4 
5 


Coolant pipe 2 
Water pump housing 
Pin 


1 
1 
2 










6 


Oil delivery pipe 


1 





4-55 



OIL FILTER, WATER PUMP AND CRANKCASE COVER 

(RIGHT) 



ENG 



% 



20 Nm (2.0 m -kg, 14 ft -lb) 




15 11 |\l 10 Nm (1.0 m -kg, 7.2 ft- lb) 



10 Nm (1.0 m -kg, 7.2 ft -lb) 



14 Nm (1.4 m -kg, 10 ft -lb) 



Extent of removal 


Order 


Part name 


Q'ty 


Remarks 


I 




7 


Oil hose 


1 




6 




8 


Kick starter 


1 




I © 


9 


Crankcase cover (right) 


1 








10 


Gasket 


1 








11 


Dowel pin/O-ring 


4/2 








12 


Impeller 


1 








13 


Plain washer 


1 




Q 


D 


14 
15 


Impeller shaft 
Oil seal 1 


1 
1 


- Refer to "REMOVAL POINTS". 






16 


Oil seal 2 


1 




. 




17 


Bearing 


1 





4-56 



OIL FILTER, WATER PUMP AND CRANKCASE COVER 

(RIGHT) 



ENG 



% 




REMOVAL POINTS 

EC4G3110 

Impeller shaft 

1 . Remove: 

• Impeller© 

• Plain washer © 

• Impeller shaft (3) 

NOTE: 



Hold the impeller shaft on its width across the 
flats ® with spanners, etc. and remove the 
impeller. 



Oil seal 
NOTE: _ 



It is not necessary to disassemble the water 
pump, unless there is an abnormality such as 
excessive change in coolant level, discolora- 
tion of coolant, or milky transmission oil. 



1 . Remove: 

• Bearing © 

• Oil seal © 



INSPECTION 

EC444200 

Impeller shaft 

1. Inspect: 

• Impeller shaft © 
Bend/wear/damage -^ Replace. 
Fur deposits -^ Clean. 



4-57 



OIL FILTER, WATER PUMP AND CRANKCASE COVER 

(RIGHT) 



ENG 



% 




EC4H4600 



Bearing 

1. Inspect: 
• Bearing 
Rotate inner race with a finger. 
Rough spot/seizure -^ Replace. 



EC444400 



Oil seal 

1. Inspect: 
• Oil seal 
Wear/damage -^ Replace. 




ASSEMBLY AND INSTALLATION 

EC4G5110 

Oil seal 

1. Install: 

• Oil seal EE3 

NOTE: 

• Apply the lithium soap base grease on the oil 
seal lip. 

• Install the oil seal with its manufacture's 
marks or numbers facing inward. 

Bearing 

1. Install: 

• Bearing © 

NOTE: 

Install the bearing by pressing its outer race 
parallel. 



4-58 



OIL FILTER, WATER PUMP AND CRANKCASE COVER 

(RIGHT) 



ENG 



% 




EC4G5220 

Impeller shaft 

1. Install: 

• Impeller shaft © 

• Plain washer © 

• Impeller© 



14 Nm (1.4 m kg, 10 ft lb) 



NOTE: 

• Take care so that the oil seal lip is not dam- 
aged or the spring does not slip off its posi- 
tion. 

• When installing the impeller shaft, apply the 
engine oil on the oil seal lip, bearing and 
impeller shaft. And install the shaft while 
turning it. 

• Hold the impeller shaft on its width across 
the flats ® with spanners, etc. and install the 
impeller. 



Crankcase cover (right) 

1. Install: 

• Dowel pin © 

• O-ring © 

• Collar © 

• Gasket © 



2. Install: 

• Crankcase cover (right) © 



Bolt 



10 Nm (1.0 m kg, 7.2 ft lb) 



NOTE: 

• Apply the engine oil on the impeller shaft 
end. 

• When installing the crankcase cover onto the 
crankcase, be sure that the impeller shaft 
end © aligns with the balancer end slot ©. 

• Tighten the bolts in stage, using a crisscross 
pattern. 



4-59 



OIL FILTER, WATER PUMP AND CRANKCASE COVER 

(RIGHT) 



ENG 



% 




Kick crank 

1. Install: 

• Kick starter © 

• Plain washer 

• Bolt (kick starter) 



SM- \\ 33 Nm (3.3 m • kg, 24 ft • lb) 



NOTE: 

Install the kick starter so that the kick starter is 
as vertical as possible with the distance ® 
between the kick starter and the frame being 
5 mm (0.20 in) or more. 




2. Install: 

• Oil hose © 



Bolt (oil hose) © 



10 Nm (1.0 m kg, 7.2 ft lb) 



3. Install: 

• Copper washer © 

• Oil delivery pipe © 

• Union bolt (M8) ® 



18 Nm (1.8 m -kg, 13 ft lb) 



Union bolt (M10)® 



20 Nm (2.0 m -kg, 14 ft -lb) 



Water pump housing 

1. Install: 

• Dowel pin © 

• O-ring © EEH 



4-60 



OIL FILTER, WATER PUMP AND CRANKCASE COVER 

(RIGHT) 



ENG 



% 




2. Install: 

• Water pump housing © 

• Bolt (water pump housing) © 



10 Nm (1.0 m kg, 7.2 ft lb) 



• Plain washer ® ieem 

• Coolant drain bolt 



10 Nm (1.0 m kg, 7.2 ft lb) 



3. Install: 

• O-ring 

• Coolant pipe © 

• Bolt (coolant pipe) © 



|\|lONm(1.0mkg,7.2ftlb) 



Oil filter 

1. Install: 

• Oil filter © 

• O-ring © EH3 

• Oil filter cover © 

• Bolt (oil filter cover) 



10 Nm (1.0 m -kg, 7.2 ft -lb) 



4-61 



BALANCER 



ENG 



% 



BALANCER 

BALANCER 





50 Nm (5.0 m • kg, 36 ft • lb) 



Extent of removal: 




© Balancer drive gear 




© Balancer 


Extent of removal 


Order 


Part name 


Q'ty 


Remarks 






BALANCER REMOVAL 






Preparation for removal 




Clutch housing 
Crankcase cover (right) 

Stator 




Refer to "CLUTCH" section. 
Refer to "OIL FILTER, WATER PUMP AND 
CRANKCASE COVER (RIGHT)" section. 
Refer to "CDI MAGNETO" section. 


c 


©1 


1 
2 
3 


Nut (primary drive gear) 
Nut (balancer) 
Lock washer 




\ Refer to "REMOVAL POINTS". 






4 
5 


Primary drive gear 
Balancer drive gear 






1 


6 


Lock washer 






© 


7 


Balancer driven gear 






I 


8 


Balancer 




Refer to "REMOVAL POINTS". 



4-62 



BALANCER 



ENG 



% 




REMOVAL POINTS 

Balancer drive gear and balancer driven 

gear 

1 . Straighten the lock washer tab. 

2. Loosen: 

• Nut (primary drive gear) © 

• Nut (balancer) © 

NOTE: 

Place an aluminum plate ® between the teeth 
of the balancer drive gear © and driven gear 

©■ 



Balancer 

1 . Remove: 
• Balancer © 

NOTE: 



When removing the balancer shaft, align the 
center of the balancer shaft weight ® along 
the line connecting the centers of the crank- 
shaft and balancer shaft. 



INSPECTION 

Primary drive gear, balancer drive gear and 

balancer driven gear 

1. Inspect: 

• Primary drive gear © 

• Balancer drive gear © 

• Balancer driven gear © 
Wear/damage -^ Replace. 



Balancer 

1. Inspect: 
• Balancer 
Cracks/damage -^ Replace. 



4-63 



BALANCER 



ENG 



% 




ASSEMBLY AND INSTALLATION 
Balancer, balancer drive gear and balancer 
driven gear 

1. Install: 

• Balancer © 

NOTE: 

When installing the balancer shaft, align the 
center of the balancer shaft weight ® along 
the line connecting the centers of the crank- 
shaft and balancer shaft. 

2. Install: 

• Balancer driven gear © 

NOTE: 

Install the balancer driven gear onto the bal- 
ancer while aligning the punch mark ® on the 
balancer driven gear with the lower spline (b) 
on the balancer end. 



3. Install: 

• Balancer drive gear © 

NOTE: 

• Align the punched mark ® on the balancer 
drive gear with the punched mark © on the 
balancer driven gear. 

• Align the punched mark © on the balancer 
drive gear with the lower spline 0) on the 
crankshaft. 

4. Install: 

• Lock washer © 

• Nut (balancer) © 



50 Nm (5.0 m ■ kg, 36 ft ■ lb) 



• Primary drive gear © 

• Nut (primary drive gear) © 



75 Nm (7.5 m • kg, 54 ft • lb) 



NOTE: 

• Install the primary drive gear with its stepped 
side (b) facing the engine. 

• Place an aluminum plate ® between the 
teeth of the balancer drive gear © and 
driven gear ©. 

5. Bend the lock washer tab. 



4-64 



OIL PUMP 



ENG 



% 



OIL PUMP 

OIL PUMP 




IS1SM 1 



10 Nm (1.0 m -kg, 7.2 ft -lb) 



2 Nm (0.2 m -kg, 1.4 ft -lb) 




Extent of removal 






© Oil pump removal 




© Oil pump disassembly 


Extent of removal 


Order 


Part name 


Q'ty 


Remarks 






OIL PUMP REMOVAL AND DIS- 
ASSEMBLY 






Preparation for removal 




Clutch housing 
Crankcase cover (right) 




Refer to "CLUTCH" section. 

Refer to "OIL FILTER, WATER PUMP AND 

CRANKCASE COVER (RIGHT)" section. 








1 
2 


Circlip 
Plate washer 






c 


) 




3 
4 
5 


Oil pump drive gear 
Oil pump assembly 
Dowel pin 






d 


>\ 


6 


Outer rotor 2 






-J 


7 


Circlip 










8 


Inner rotor 2 










9 


Pin 










10 
11 


Oil pump cover 
Outer rotor 1 










12 


Inner rotor 1 







4-65 



OIL PUMP 



ENG 



% 



ISEffl l 



10 Nm (1.0 m -kg, 7.2 ft- lb) 



2 Nm (0.2 m -kg, 1.4 ft -lb) 




Extent of removal 


Order 


Part name 


Q'ty 


Remarks 


Q 


D 


13 
14 
15 
16 


Pin 

Washer 

Oil pump drive shaft 

Rotor housing 


1 
1 
1 
1 





4-66 



OIL PUMP 



ENG 



% 



INSPECTION 
Oil pump 

1. Inspect: 

• Oil pump drive gear 

• Oil pump driven gear 

• Rotor housing 

• Oil pump cover 
Cracks/wear/damage -^ Replace. 




2. Measure: 

• Tip clearance ® 

Between the inner rotor © and the 
outer rotor ©. 

• Tip clearance (b) 

Between the outer rotor © and the rotor 

housing ©. 

Out of specification -^ Replace the oil 

pump. 




Tip clearance ®: 

0.12 mm or less 

(0.0047 in or less) 

<Limit>: 0.20 mm (0.008 in) 
Tip clearance ©: 

0.09 ~ 0.17 mm (0.0035 ~ 0.0067 in) 

<Limit>: 0.24 mm (0.009 in) 
Side clearance ©: 

0.03 ~ 0.10 mm (0.0012 ~ 0.0039 in) 

<Limit>: 0.17 mm (0.007 in) 



3. Check: 

• Unsmooth -^ Repeat steps #1 and #2 
or replace the defective parts. 



ASSEMBLY AND INSTALLATION 
Oil pump 



1. 



Install: 

• Oil pump drive shaft © 

• Washer © 

• Pin© 

• Inner rotor 1 © 

NOTE: 

• Apply the engine oil on the oil pump drive 
shaft and inner rotor 1 . 

• Fit the pin into the groove in the inner rotor 1 . 



4-67 



OIL PUMP 



ENG 



% 




2. Install: 

• Outer rotor 1 © 

NOTE: 



Apply the engine oil on the outer rotor 1 . 



3. Install: 

• Oil pump cover © 



Screw (oil pump cover) © 



2 Nm (0.2 m kg, 1.4 ft lb) 



• Pin© 

• Inner rotor 2 © 

• Circlip © 



NOTE: 

• Apply the engine oil on the oil pump drive 
shaft end and inner rotor 2. 

• Fit the pin into the groove in the inner rotor 2. 




4. Install: 

• Outer rotor 2 © 

• Dowel pin © 

• Oil pump assembly © 

• Bolt (oil pump assembly) 
[L = 30 mm (1.18 in)]® 





\ 10 Nm (1.0 m -kg, 7.2 ft -lb) 


• Bolt (oil pump assembly) 
[L = 25 mm (0.98 in)] © 




\ 10 Nm (1.0 m -kg, 7.2 ft -lb) 


MHTF- 





Apply the engine oil on the outer rotor 2. 

5. Install: 

• Oil pump drive gear © 

• Plate washer © 

• Circlip © EEH 

NOTE: 

Apply the engine oil on the oil pump drive gear 
inner circumference. 



4-68 



KICK AXLE AND SHIFT SHAFT 



ENG 



% 



KICK AXLE AND SHIFT SHAFT 

KICK AXLE AND SHIFT SHAFT 





£|\ |\| 30 Nm (3.0 m ♦ kg, 22 ft » lb) 



n^\ v:,7 > _ 

A jg \ ^/^ Q IX1 10 Nm (1.0 m- kg, 7.2 ft- lb) 



Extent of removal: 






© Kick axle removal 
(3) Shift shaft removal 




© Kick axle disassembly 
® Segment removal 


Extent of removal 


Order 


Part name 


Q'ty 


Remarks 






KICK AXLE AND SHIFT SHAFT 
REMOVAL 






Preparation for removal 




Oil pump 




Refer to "OIL PUMP" section. 


1 




1 
2 


Kick idle gear 
Kick axle assembly 




Refer to "REMOVAL POINTS". 


d 


D 


3 
4 
5 


Spring guide 
Torsion spring 
Ratchet wheel 










6 

7 


Kick gear 
Kick axle 






©| 


8 


Plain washer 






c 


a (^ 


9 
10 


Shift pedal 
Shift shaft 






s/ V. 




11 


Collar 






■ 






12 


Torsion spring 







4-69 



KICK AXLE AND SHIFT SHAFT 



ENG 



% 




^\ \\\ 30 Nm (3.0 m - kg, 22 ft - lb) 



n^A V- 17 >* n 

A jg \ ^ s' Q |X|lONm(1.0m.kg,7.2ft.|b) 



Extent of removal 


Order 


Part name 


Q'ty 


Remarks 






13 


Roller 


1 








14 
15 


Shift guide 

Shift lever assembly 


1 


\ Refer to "REMOVAL POINTS". 






16 


Shift lever 


1 








17 


Pawl 


2 




© 


18 


Pawl pin 


2 








19 


Spring 


2 








20 


Bolt (stopper lever) 


1 








21 


Stopper lever 


1 








22 


Torsion spring 


1 




, 




23 


Segment 


1 


Refer to "REMOVAL POINTS". 



4-70 



KICK AXLE AND SHIFT SHAFT 



ENG 



% 




REMOVAL POINTS 

EC4B3101 

Kick axle assembly 

1 . Remove: 

• Kick axle assembly © 

NOTE: 



Unhook the torsion spring © from the hole ® 
in the crankcase. 



EC4C3101 

Shift guide and shift lever assembly 

1 . Remove: 

• Bolt (shift guide) 

• Shift guide © 

• Shift lever assembly © 

NOTE: 

The shift lever assembly is disassembled at 
the same time as the shift guide. 

EC4N3100 

Segment 

1 . Remove: 

• Bolt (segment) © 

• Segment © 

NOTE: 

Turn the segment counterclockwise until it 
stops and loosen the bolt. 



INSPECTION 

EC4C4200 

Kick axle and ratchet wheel 

1. Check: 

• Ratchet wheel © smooth movement 
Unsmooth movement -> Replace. 

• Kick axle © 
Wear/damage -^ Replace. 

• Spring © 
Broken -^ Replace. 

EC4C4300 

Kick gear, kick idle gear and ratchet wheel 

1. Inspect: 

• Kick gear © 

• Kick idle gear © 

• Ratchet wheel © 

• Gear teeth ® 

• Ratchet teeth © 
Wear/damage -> Replace. 



4-71 



KICK AXLE AND SHIFT SHAFT 



ENG 



% 




EC4B4400 

Shift shaft 

1. Inspect: 

• Shift shaft © 
Bend/damage -^ Replace. 

• Spring © 
Broken -^ Replace. 



EC4C4100 

Shift guide and shift lever assembly 

1. Inspect: 

• Shift guide © 

• Shift lever © 

• Pawl © 

• Pawl pin © 

• Spring © 
Wear/damage -^ Replace. 



EC4B4500 

Stopper lever 

1. Inspect: 

• Stopper lever © 
Wear/damage -^ Replace. 

• Torsion spring © 
Broken -^ Replace. 



EC4C5000 

ASSEMBLY AND INSTALLATION 
Segment 

1. Install: 

• Segment © 

• Bolt (segment) 



30 Nm (3.0 m • kg, 22 ft • lb) 



NOTE: 

Align the notch ® on the segment with the pin 
©on the shift cam. 



4-72 



KICK AXLE AND SHIFT SHAFT 



ENG 



% 




EC4B51 1 1 

Stopper lever 

1. Install: 

• Torsion spring © 

• Stopper lever © 

• Bolt (stopper lever) © 



10 Nm (1.0 m kg, 7.2 ft lb) 



NOTE: 

Align the stopper lever roller with the slot on 
segment. 

Shift guide and shift lever assembly 

1. Install: 

• Spring © 

• Pawl pin © 

• Pawl © 

To shift lever @. 

NOTE: 

Apply the engine oil on the springs, pawl pins 
and pawls. 

2. Install: 

• Shift lever assembly © 
To shift guide ©. 



3. Install: 

• Shift lever assembly © 

• Shift guide © 

NOTE: 

• The shift lever assembly is installed at the 
same time as the shift guide. 

• Apply the engine oil on the bolt (segment) 
shaft. 



4. Install: 

• Bolt (shift guide) © 



Sl=>- |\ 10 Nm (1.0 m -kg, 7.2 ft -lb) 



4-73 



KICK AXLE AND SHIFT SHAFT 



ENG 



% 




EC4C5301 

Shift shaft 

1. Install: 

• Roller© 

• Collar © 

• Torsion spring 

• Shift shaft 

NOTE: 



Apply the engine oil on the roller and shift 
shaft. 

2. Install: 

• Shift pedal © 



Bolt (shift pedal) 



12 Nm (1.2 m kg, 8.7 ft lb) 



NOTE: 

When installing the shift pedal onto the shift shaft, 
be sure that the center of the shift pedal is about 
2 mm (0.08 in) ® above the top of the footrest. 



Kick axle assembly 

1. Install: 

• Kick gear © 

• Plain washer © 

• Circlip © ES3 

• Ratchet wheel © 

• Spring ® 

• Plain washer © 

• Circlip © EE3 
To kick axle ®. 

NOTE: 

• Apply the molybdenum disulfide oil on the 
inner circumferences of the kick gear and 
ratchet wheel. 

• Align the punch mark ® on the ratchet wheel 
with the punch mark © on the kick axle. 




2. Install: 

• Torsion spring © 
To kick axle ©. 

NOTE: 

Make sure the stopper ® of the torsion spring 
fits into the hole © on the kick axle. 



4-74 



KICK AXLE AND SHIFT SHAFT 



ENG 



% 




Install: 

• Spring guide © 



NOTE: 

Slide the spring guide into the kick axle, make 
sure the groove ® in the spring guide fits on 
the stopper of the torsion spring. 



4. Install: 

• Kick axle assembly © 

• Plain washer © 

NOTE: 

• Apply the molybdenum disulfide grease on 
the contacting surfaces of the kick axle stop- 
per ® and stopper plate ©. 

• Apply the engine oil on the kick axle. 

• Slide the kick axle assembly into the crank- 
case and make sure the kick axle stopper fits 
into the stopper plate. 




5. Hook: 

• Torsion spring © 



NOTE: 

Turn the torsion spring clockwise and hook 
into the proper hole ® in the crankcase. 



Kick idle gear 

1. Install: 

• Kick idle gear © 

• Plain washer © 

• Circlip © ESS 

NOTE: 

• Install the kick idle gear with its depressed 
side ©toward you. 

• Apply the engine oil on the kick idle gear 
inner circumference. 



4-75' 



CDI MAGNETO 



ENG 



% 



EC4L0000 

CDI MAGNETO 





10 Nm (1.0 nr kg, 7.2 ft -lb) 



Extent of removal: 




© CDI magneto removal 






Extent of removal 


Order 


Part name 


Q'ty 


Remarks 






CDI MAGNETO REMOVAL 






Preparation for removal 




Seat and fuel tank 

Bolt [radiator (left)] 

Disconnect the CDI magneto lead. 




Refer to "SAET, FUEL TANK AND SIDE 

COVERS" section. 

Refer to "RADIATOR" section. 


• 




1 


Crankcase cover (left) 


1 








2 


Gasket 


1 








3 


Dowel pin 


2 




c 


) 


4 
5 


Nut (rotor) 
Rotor 


1 
1 


i Use special tool. 

\ Refer to "REMOVAL POINTS". 






6 


Stator 


1 




. 




7 


Woodruff key 


1 





4-76 



CDI MAGNETO 



ENG 



% 




EC4L3000 

REMOVAL POINTS 

EC4L3101 

Rotor 

1 . Remove: 

• Nut (rotor) © 

• Plain washer 

Use the rotor holding tool ®. 



f* 



Rotor holding tool: 
YU-1 235/90890-01 235 



2. Remove: 
• Rotor © 
Use the flywheel puller ©. 



^ 



Flywheel puller: 
YM-1 189/90890-01 189 



NOTE: 

When installing the flywheel puller, turn it 
counterclockwise. 




EC4L4000 

INSPECTION 

EC4L4101 

CDI magneto 

1. Inspect: 

• Rotor inner surface ® 

• Stator outer surface (b) 

Damage -^ Inspect the crankshaft 
runout and crankshaft bearing. 
If necessary, replace CDI magneto and/ 
or stator. 

EC4L4200 

Woodruff key 

1. Inspect: 

• Woodruff key © 
Damage -^ Replace. 



4-77 



CDI MAGNETO 



ENG 



% 




EC4L5000 

ASSEMBLY AND INSTALLATION 
CDI magneto 

1. Install: 

• Stator © 

• Screw (stator) ® 



10 Nm (1.0 m kg, 7.2 ft lb) 



NOTE: 

• Apply the sealant to the grommet of the CDI 
magneto lead. 

• Tighten the screws using the T30 bit. 




Quick gasket®: 
ACC-QUICK-GS-KT 

YAMAHA Bond No. 1215: 
90890-85505 




2. Install: 

• Woodruff key © 

• Rotor ® 

NOTE: 

• Clean the tapered portions of the crankshaft 
and rotor. 

• When installing the woodruff key, make sure 
that its flat surface ® is in parallel with the 
crankshaft center line ©. 

• When installing the rotor, align the keyway © 
of the rotor with the woodruff key. 




3. Install: 

• Plain washer 

• Nut (rotor) © 



56 Nm (5.6 m • kg, 40 ft • lb) 



Use the rotor holding tool ©. 



P> 



Rotor holding tool: 
YU-1 235/90890-01 235 



4-78 



CDI MAGNETO 



ENG 



% 




4. Connect: 

• CDI magneto lead 
Refer to "CABLE ROUTING DIA- 
GRAM" section in the CHAPTER 2. 



5. Install: 

• Gasket [crankcase cover (left)] 

• Crankcase cover (left) © 

• Hose holder (cylinder head breather 
hose) © 

• Bolt [crankcase cover (left)] 



10 Nm (1.0 m kg, 7.2 ft lb) 



NOTE: 

Tighten the bolts in stage, using a crisscross 
pattern. 



4-79 



ENGINE REMOVAL 



ENG 



% 



EC4M0000 

ENGINE REMOVAL 



26 Nm (2.6 m -kg, 19 ft -lb) 



\ 


10 Nm (1.0 m- 


kg, 


7.2 ft ■ 


lb) 




X 


55 Nm (5.5 m 


•kg 


40 ft 


•lb) 



75 Nm (7.5 m - kg, 54 ft - lb) 



85 Nm (8.5 m - kg, 61 ft - lb) 




10 Nm (1.0 m -kg, 7.2 ft -lb) 



8 Nm (0.8 m • kg, 5.8 ft • lb) 



Extent of removal 


Order 


Part name 


Q'ty 


Remarks 






ENGINE REMOVAL 






Preparation for removal 




Hold the machine by placing the 
suitable stand under the frame. 




| A WARNING | 


Support the machine securely so there is no 






Seat and fuel tank 




danger of it falling over. 


Refer to "SEAT, FUEL TANK AND SIDE 










COVERS" section. 






Carburetor 




Refer to "CARBURETOR" section. 






Exhaust pipe and silencer 




Refer to "EXHAUST PIPE AND 
SILENCER" section. 






Clutch cable and guide 




Disconnect at engine side. 






Radiator 




Refer to "RADIATOR" section. 






Shift pedal 




Refer to "CDI MAGNETO" section. 






Cylinder head breather hose and 




Refer to "CAMSHAFTS" section. 






oil tank breather hose 










Drain the engine oil 




Refer to "ENGINE OIL REPLACEMENT" 
section in the CHAPTER 3. 






Ignition coil 










Disconnect the CDI magneto lead. 







4-80 



ENGINE REMOVAL 



ENG 



% 



26 Nm (2.6 m -kg, 19 ft -lb) 



\ 


10 Nm (1.0 m. 


kg, 


7.2 ft ■ 


lb) 




X 


55 Nm (5.5 m 


•kg 


40 ft 


-lb) 



75 Nm (7.5 m - kg, 54 ft - lb) 



85 Nm (8.5 m - kg, 61 ft - lb) 




10 Nm (1.0 m -kg, 7.2 ft -lb) 



8 Nm (0.8 m • kg, 5.8 ft • lb) 



Extent of removal: 




© Engine removal 






Extent of removal 


Order 


Part name 


Q'ty 


Remarks 






1 


Engine skid plate (front) 


1 








2 


Neutral switch 


1 








3 


Oil hose 


2 








4 


Chain cover 


1 








5 


Nut (drive sprocket) 


1 








6 


Lock washer 


1 


- Refer to "REMOVAL POINTS". 






7 


Drive sprocket 


1 




c 


^ 


8 


Clip 


1 




J 


9 


Bolt (brake pedal) 


1 








10 


Brake pedal 


1 








11 


Engine upper bracket (right) 


1 








12 


Engine upper bracket (left) 


1 








13 


Engine lower bracket 


2 








14 


Engine mounting bolt 


3 








15 
16 


Pivot shaft 
Engine 


1 
1 


} Refer to "REMOVAL POINTS". 



4-81 



ENGINE REMOVAL 



ENG 



% 




EC4M3000 

REMOVAL POINTS 

EC4F3100 

Drive sprocket 

1 . Remove: 

• Nut (drive sprocket) © 

• Lock washer ® 

NOTE: 



• Straighten the lock washer tab. 

• Loosen the nut while applying the rear brake. 

2. Remove: 

• Drive sprocket © 

• Drive chain ® 

NOTE: 

Remove the drive sprocket together with the 
drive chain. 



EC4M3301 

Engine removal 

1 . Remove: 
• Pivot shaft © 

NOTE: 

If the pivot shaft is pulled all the way out, the 
swingarm will come loose. If possible, insert a 
shaft of similar diameter into the other side of 
the swingarm to support it. 



2. 



Remove: 
• Engine © 



From right side. 



NOTE: 

Make sure that the couplers, hoses and cables 
are disconnected. 



4-82 



ENGINE REMOVAL 



ENG 



% 





EC4M5000 

ASSEMBLY AND INSTALLATION 
Engine installation 

1. Install: 

• Engine © 

Install the engine from right side. 

• Pivot shaft © 



85 Nm (8.5 m • kg, 61 ft • lb) 



• Engine mounting bolt (lower) 



69 Nm (6.9 m • kg, 50 ft • lb) 



• Engine lower bracket 

• Bolt (engine bracket) © 



34 Nm (3.4 m • kg, 24 ft • lb) 



Engine mounting bolt (front) 



65 Nm (6.5 m • kg, 47 ft • lb) 



• Engine upper bracket (right) © 

• Engine upper bracket (left) ® 

• Bolt (engine bracket) ® 



55 Nm (5.5 m ■ kg, 40 ft • lb) 



Engine mounting bolt (upper) (jg) 



55 Nm (5.5 m • kg, 40 ft • lb) 



• Engine skid plate (front) © 

• Bolt (engine skid plate) @ 



IX |10Nm (1.0 m -kg, 7.2 ft -lb) 



NOTE: 

Apply the molybdenum disulfide grease on the 
pivot shaft. 

EC4M5211 

Brake pedal 



1. 



Install: 

• Spring 

• Brake pedal © 

• O-ring © 



Bolt (brake pedal) © 



26 Nm (2.6 m -kg, 19 ft -lb) 



• Clip® 

NOTE: 

• Apply the lithium soap base grease on the 
bolt, O-rings and brake pedal bracket. 

• Install the clip with its stopper portion ® fac- 
ing inward. 

Drive sprocket 

1. Install: 

• Drive sprocket © 

• Drive chain © 

NOTE: 

Install the drive sprocket together with the 
drive chain. 



4-83 



ENGINE REMOVAL 



ENG 



% 




2. Install: 

• Lock washer © EE3 

• Nut (drive sprocket) © 



75 Nm (7.5 m ■ kg, 54 ft ■ lb) 



NOTE: 

Tighten the nut while applying the rear brake. 



3. Bend the lock washer tab to lock the nut. 

4. Install: 

• Chain guide 

• Chain cover © 

• Screw (chain cover) © 



8 Nm (0.8 m • kg, 5.8 ft • lb) 



5. Install: 

• O-ring © 

• Dowel pin © 

• Oil hose © 

• Bolt (oil hose) © 



10 Nm (1.0 m -kg, 7.2 ft -lb) 



NOTE: 

Apply the lithium soap base grease on the O- 
ring. 




6. Install: 






• Spring (T) 






• Pin© 






• O-ring © UMH 






• Neutral switch @ 






• Screw (neutral switch) © 






EEh- |\ 4 Nm (0.4 m • kg, 


2.9 ft 


•lb) 


NnTF- 


Apply the lithium soap base grease on 


the 0- 


ring. 







4-84 



CRANKCASE AND CRANKSHAFT 



ENG 



% 



CRANKCASE AND CRANKSHAFT 

CRANKCASE AND CRANKSHAFT 



10 Nm (1.0 m -kg, 7.2 ft -lb) 




10 Nm (1.0 m -kg, 7.2 ft -lb) 



10 Nm (1.0 m -kg, 7.2 ft -lb) 



Extent of removal: 



© Crankcase separation 



© Crankshaft removal 



Extent of removal 


Order 


Part name 


Q'ty 


Remarks 






CRANKCASE SEPARATION 






Preparation for removal 




Engine 
Piston 

Balancer 

Kick axle assembly 




Refer to "ENGINE REMOVAL" section. 
Refer to "CYLINDER AND PISTON" sec- 
tion. 
Refer to "BALANCER" section. 

l Refer to "KICK AXLE AND SHIFT 
\ SHAFT" section. 






Segment 








Stator 




Refer to "CDI MAGNETO" section. 




. 


. 


1 
2 


Timing chain guide (rear) 
Timing chain 


1 
1 










3 


Bolt (50 mm) 


6 










4 


Bolt (60 mm) 


3 




© d 


D 


5 


Bolt (75 mm) 


3 










6 


Hose guide 


1 


- Refer to "REMOVAL POINTS". 








7 


Clutch cable holder 


1 










8 


Crankcase (right) 


1 




■ 






9 


Crankcase (left) 


1 





4-85 



CRANKCASE AND CRANKSHAFT 



ENG 



% 



10 Nm (1.0 m -kg, 7.2 ft -lb) 




10 Nm (1.0 m -kg, 7.2 ft -lb) 



10 Nm (1.0 m -kg, 7.2 ft -lb) 



Extent of removal 


Order 


Part name 


Q'ty 


Remarks 




10 
11 
12 


Oil strainer 

Oil delivery pipe 2 

Crankshaft 


1 
1 
1 


Use special tool. 

Refer to "REMOVAL POINTS". 



4-86 



CRANKCASE AND CRANKSHAFT 



ENG 



% 



CRANKCASE BEARING 



10 Nm (1.0 m -kg, 7.2 ft -lb) 




Extent of removal: 



© Crankcase bearing removal 



Extent of removal 


Order 


Part name 


Q'ty 


Remarks 


Preparation for removal 




CRANKCASE BEARING 
REMOVAL 

Transmission 

Shift cam and shift fork 




i Refer to "TRANSMISSION, SHIFT 
I" CAM AND SHIFT FORK" section. 


i 


1 
2 


Oil seal 
Bearing 


3 
10 


Refer to "REMOVAL POINTS". 



4-87 



CRANKCASE AND CRANKSHAFT 



ENG 



% 




REMOVAL POINTS 
Crankcase 

1 . Separate: 

• Crankcase (right) 

• Crankcase (left) 



Separation steps: 

• Remove the crankcase bolts, hose guide 
and clutch cable holder. 



NOTF- 




Loosen each bolt 1/4 of a turn at a time and 


after all the bolts are loosened, 


remove 


them. 




• Remove the crankcase (right). 




NOTF- 





• Place the crankcase with its left side 
downward and split it by inserting a screw- 
driver tip into the splitting slit ® in the 
crankcase. 

• Lift the crankcase (right) horizontally while 
lightly patting the case splitting slit and 
engine mounting boss using a soft ham- 
mer, and leave the crankshaft and trans- 
mission with the crankcase (left). 



Use soft hammer to tap on the case half. 
Tap only on reinforced portions of case. 
Do not tap on gasket mating surface. 
Work slowly and carefully. Make sure the 
case halves separate evenly. If one end 
"hangs up", take pressure off the push 
screw, realign, and start over. If the 
cases do not separate, check for a 
remaining case screw or fitting. Do not 
force. 

• Remove the dowel pins and O-ring. 



4-88 



CRANKCASE AND CRANKSHAFT 



ENG 



% 





^\^ 






ri! * 






Crankshaft 

1 . Remove: 

• Crankshaft © 
Use the crankcase separating tool 



^ 



Crankcase separating tool: 
YU-1135-A/90890-01135 



II ' 

Do not use a hammer to drive out the 
crankshaft. 

Crankshaft bearing 

1 . Remove: 

• Bearing © 

NOTE: 

• Remove the bearing from the crankcase by 
pressing its inner race. 

• Do not use the removed bearing. 

INSPECTION 

Timing chain and timing chain guide 

1. Inspect: 

• Timing chain 

Cracks/stiff -> Replace the timing chain 
and camshaft sprocket as a set. 

2. Inspect: 

• Timing chain guide 
Wear/damage -> Replace. 

EC4N4101 

Crankcase 

1. Inspect: 

• Contacting surface ® 
Scratches -> Replace. 

• Engine mounting boss ©, crankcase 
Cracks/damage -> Replace. 



2. Inspect: 

• Bearing 

Rotate inner race with a finger. 
Rough spot/seizure -» Replace. 

3. Inspect: 

• Oil seal 
Wear/damage -» Replace. 



4-89 



CRANKCASE AND CRANKSHAFT 



ENG 



% 




EC4N4201 

Crankshaft 

1. Measure: 

• Runout limit (a) 

• Small end free play limit (b) 

• Connecting rod big end side clearance 
© 

• Crank width 0) 

Out of specification -^ Replace. 

Use the dial gauge and a thickness 

gauge. 



y> 


Dial gauge and stand: 
YU-3097/90890-01252 




s 




Standard 


<Limit> 


Runout 
limit: 


0.03 mm 
(0.0012 in) 


0.05 mm 
(0.002 in) 


Small end 
free play: 


0.4 - 1.0 mm 
(0.016 -0.039 in) 


2.0 mm 
(0.08 in) 


Side 
clearance: 


0.15 ~ 0.45 mm 
(0.0059 -0.0177 in) 


0.50 mm 
(0.02 in) 


Crack 
width: 


61.95 ~ 62.00 mm 
(2.439 ~ 2.441 in) 


— 




Oil strainer 

1. Inspect: 
• Oil strainer 
Damage -^ Replace. 



Oil delivery pipe 

1. Inspect: 

• Oil delivery pipe 
Cracks/damage -^ Replace. 

• Oil delivery pipe holes © 

Clogged -^ Blow out with compressed 
air. 



4-90 



CRANKCASE AND CRANKSHAFT 



ENG 



% 




EC4N5000 

ASSEMBLY AND INSTALLATION 
Crankshaft bearing 

1. Install: 

• Bearing E^3 

• Bearing stopper 

• Bolt (bearing stopper) 



P"]-^ |X 10Nm(1.0mkg, 7.2ftlb) 


Screw (bearing stopper) 


E5h- IX 10Nm (1.0 m. kg, 7.2 ft- lb) | 


Screw [bearing stopper (crankshaft)] © 


IX 10 Nm (1.0 m. kg, 7.2 ft- lb) | 


To crankcase (left and right). 



NOTE: 

• Install the bearing by pressing its outer race 
parallel. 

• To prevent the screw [bearing stopper 
(crankshaft)] from becoming loose, crush the 
screw head periphery ® into the concave © 
using a punch etc. In so doing, take care not 
to damage the screwdriver receiving hole in 
the screw head. 




Crankshaft 

1. Install: 

• Crankshaft © 
Use the crankshaft installing tool ©, ©, 

© and ©. 



^ 



Crankshaft installing pot ©: 

YU-90050/90890-01274 
Crankshaft installing bolt ©: 

YU-90050/90890-01275 
Adaptor (M1 2)®: 

YU-90063/90890-01278 
Spacer (crankshaft installer) ©: 

YM-91 044/90890-04081 



S For USA and CDN 

U Except for USA and CDN 



4-91 



CRANKCASE AND CRANKSHAFT 



ENG 



% 



NOTE: 

• Hold the connecting rod at top dead center 
with one hand while turning the nut of the 
installing tool with the other. Operate the 
installing tool until the crankshaft bottoms 
against the bearing. 

• Before installing the crankshaft, clean the 
contacting surface of crankcase. 

cai n- 



Do not use a hammer to drive in the crank- 
shaft. 




2. Check: 

• Shifter operation 

• Transmission operation 
Unsmooth operation -^ Repair. 



3. Install: 

• Oil strainer © 



Bolt (oil strainer) © 



10 Nm (1.0 m kg, 7.2 ft lb) 



4. Apply: 
• Sealant 
On the crankcase (right) ©. 




Quick gasket®: 

ACC-QUICK-GS-KT 
YAMAHA Bond No. 1215: 

90890-85505 



NOTE: 

Clean the contacting surface of crankcase (left 
and right) before applying the sealant. 



4-92 



CRANKCASE AND CRANKSHAFT 



ENG 



% 




5. Install: 

• Dowel pin © 

• O-ring © E^3 

• Crankcase (right) 
To crankcase (left). 

NOTE: 

• Fit the crankcase (right) onto the crankcase 
(left). Tap lightly on the case with soft ham- 
mer. 

• When installing the crankcase, the connect- 
ing rod should be positioned at TDC (top 
dead center). 




6. Tighten: 

• Hose guide © 

• Clutch cable holder © 

• Bolt (clutch cable holder) 





|Y 10 Nm (1.0 m 


kg, 


7.2 ft 


lb) 


• 


Bolt (crankcase) 










|Y 12 Nm (1.2 m 


•kg, 


8.7 ft 


lb) 


NOTE: 











Tighten the crankcase tightening bolts in 
stage, using a crisscross pattern. 

7. Install: 

• Oil delivery pipe 

• O-ring E^3 

• Bolt (oil delivery pipe) 



10 Nm (1.0 m -kg, 7.2 ft -lb) 



8. Install: 

• Timing chain 

• Timing chain guide (rear) 

• Bolt (timing chain guide) 



10 Nm (1.0 m -kg, 7.2 ft -lb) 



4-93 



9. Remove: 

• Sealant 

Forced out on the cylinder mating surface. 

10. Apply: 

• Engine oil 

To the crank pin, bearing and oil deliv- 
ery hole. 

1 1 . Check: 

• Crankshaft and transmission operation. 
Unsmooth operation -^ Repair. 



TRANSMISSION, SHIFT CAM AND SHIFT FORK 



ENG 



% 



TRANSMISSION, SHIFT CAM AND SHIFT FORK 

TRANSMISSION, SHIFT CAM AND SHIFT FORK 




Extent of removal: 



© Shift fork, shift cam, main axle and drive axle removal 



Extent of removal 


Order 


Part name 


Q'ty 


Remarks 






TRANSMISSION, SHIFT CAM 










AND SHIFT FORK REMOVAL 






Preparation for removal 




Engine 

Separate the crankcase. 




Refer to "ENGINE REMOVAL" section. 
Refer to "CRANKCASE AND CRANK- 
SHAFT" section. 






1 
2 


Shift fork 1 
Shift fork 2 






C 


k 


3 


Shift cam 




- Refer to "REMOVAL POINTS". 


j 


4 


Main axle 










5 


Drive axle 






. 




6 


Collar 







4-94 



TRANSMISSION, SHIFT CAM AND SHIFT FORK 



ENG 



% 




EC4H3000 

REMOVAL POINTS 

Shift fork, shaft cam and transmission 

1 . Remove: 

• Shift forks 

• Shift cam 

• Main axle 

• Drive axle 

NOTE: 

• Tap lightly on the transmission drive axle and 
shift cam with a soft hammer to remove. 

• Remove assembly carefully. Note the posi- 
tion of each part. Pay particular attention to 
the location and direction of shift forks. 




EC4H4000 

INSPECTION 

EC4H4200 



Gears 



2. 



3. 



Inspect: 

• Matching dog ® 

• Gear teeth © 

• Shift fork groove © 
Wear/damage -> Replace. 



Inspect: 

• O-ring © 
Damage -> Replace. 

Check: 

• Gears movement 
Unsmooth movement 
replace. 



-> Repair or 



EC4H4600 



Bearing 

1. Inspect: 
• Bearing © 
Rotate inner race with a finger. 
Rough spot/seizure -^ Replace. 



4-95 



TRANSMISSION, SHIFT CAM AND SHIFT FORK 



ENG 



% 




EC4H4801 

Shift fork, shift cam and segment 

1. Inspect: 
• Shift fork © 
Wear/damage/scratches -^ Replace. 



2. Inspect: 

• Shift cam © 

• Segment © 
Bend/wear/damage -^ Replace. 



Check: 

• Shift fork movement 

Unsmooth operation 

fork. 



-^ Replace shift 



NOTE: 

For a malfunctioning shift fork, replace not only 
the shift fork itself but the two gears each adja- 
cent to the shift fork. 



ASSEMBLY AND INSTALLATION 
Transmission 

1. Install: 

• 4th pinion gear (20T) © 

• 3rd pinion gear (18T) © 

• 2nd pinion gear (16T) © 
To main axle ©. 

NOTE: 

• Apply the molybdenum disulfide oil on the 
2nd and 5th pinion gears inner circumfer- 
ence and on the end surface. 

• Apply the molybdenum disulfide oil on the 
3rd pinion gear inner circumference. 



4-96 



TRANSMISSION, SHIFT CAM AND SHIFT FORK 



ENG 



% 




frS^P= 


^s^N 






vfv 






^QNlP^ 



2. Install: 

• 2nd wheel gear (25T) © 

• 3rd wheel gear (23T) © 

• 4th wheel gear (21 T) © 

• 1st wheel gear (27T) 

• O-ring @ 

To drive axle ®. 

NOTE: 

• Apply the molybdenum disulfide oil on the 
1st, 2nd and 3rd wheel gears inner circum- 
ference and on the end surface. 

• Apply the molybdenum disulfide oil on the 
4th wheel gear inner circumference. 

• Apply the lithium soap base grease on the O- 
ring. 



3. Install: 

• Plain washer © 

• Circlip © 12^3 

NOTE: 



• Be sure the circlip sharp-edged corner ® is 
positioned opposite side to the plain washer 
and gear ©. 

• Be sure the circlip end © is positioned at 
axle spline groove 0). 



4. Install: 
• Collar © 

NOTE: 



• Apply the lithium soap base grease on the oil 
seal lip. 

• When installing the spacer into the crank- 
case, pay careful attention to the crankcase 
oil seal lip. 



4-97 



TRANSMISSION, SHIFT CAM AND SHIFT FORK 



ENG 



% 




5. Install: 

• Shift fork 1 (L) © 

• Shift fork 2 (R) ® 

• Shift cam (3) 

To main axle and drive axle. 

NOTE: 

• Apply the molybdenum disulfide oil on the 
shift fork grooves. 

• Mesh the shift fork #1 (L) with the 3rd pinion 
gear on the main axle. 

• Mesh the shift fork #2 (R) with the 4th wheel 
gear (§) on the drive axle. 



6. Install: 

• Transmission assembly © 
To crankcase (left) ®. 

NOTE: 

Apply the engine oil on the bearings and guide 
bars. 



£ ^K 














^=J 


^TL/ 


\ 7 \y W <T 


Cr^f 





7. Check: 

• Shifter operation 

• Transmission operation 
Unsmooth operation -^ Repair. 



4-98 



FRONT WHEEL AND REAR WHEEL 



CHAS 



<$%) 



EC500000 

CHASSIS 

EC590000 

FRONT WHEEL AND REAR WHEEL 

EC598000 

FRONT WHEEL 



105 Nm (10.5 m - kg, 75 ft - lb) 




10 Nm (1.0 m -kg, 7.2 ft -lb) 



Extent of removal: 






© Front wheel removal 
(3) Brake disc removal 




(2) Wheel bearing removal 




Extent of removal 


Order 


Part name 


Q'ty 


Remarks 


Preparation for removal 




FRONT WHEEL REMOVAL 

Hold the machine by placing the 
suitable stand under the engine. 




wmw\M\ma 


Support the machine securely so there is no 
danger of it falling over. 


. 


> 






1 


Hose cover 


1 






c 


) 


D 


D 


2 
3 
4 
5 


Bolt (brake hose holder) 
Bolt (axle holder) 
Nut (front wheel axle) 
Front wheel axle 


2 
4 

1 
1 


Only loosening. 
Only loosening. 












6 


Front wheel 


1 










7 


Collar 


2 










8 


Oil seal 


2 








1 d> 


9 
10 


Bearing 
Brake disc 


2 

1 


Refer to "REMOVAL POINTS". 





5-1 



FRONT WHEEL AND REAR WHEEL 



CHAS 



<$%) 



EC598100 

REAR WHEEL 



125 Nm (12.5 m -kg, 90 ft -lb) V 14 Nm (1.4 m • kg, 10 ft • lb) 

3 j— 



16 Nm (1.6 m -kg, 11 ft -lb) 



7 8 B 



42 Nm (4.2 m • kg, 30 ft * lb) 




Extent of removal: 



© Rear wheel removal 
© Brake disc removal 



© Wheel bearing removal 



Extent of removal 


Order 


Part name 


Q'ty 


Remarks 


Preparation for removal 




REAR WHEEL REMOVAL 

Hold the machine by placing the 
suitable stand under the engine. 




wmmmua 


Support the machine securely so there is no 
danger of it falling over. 




c 




d 


^ 


1 
2 


Nut (rear wheel axle) 
Rear wheel axle 


1 
1 






J 


y 


3 
4 


Chain puller 
Rear wheel 


2 

1 


Refer to "REMOVAL POINTS". 




(2) 


5 


Collar 


2 










6 

7 


Driven sprocket 
Oil seal 


1 
2 










8 


Circlip 


1 










9 


Bearing 


2 


Refer to "REMOVAL POINTS". 




© 

* 


10 


Brake disc 


1 







5-2 



FRONT WHEEL AND REAR WHEEL 



CHAS 



(fab 




/ ®f 


§\ K3>| 






" 1 




EC593000 

REMOVAL POINTS 

EC523101 

Rear wheel 

1 . Remove: 
• Wheel © 



NOTE: 

Push the wheel forward and remove the drive 
chain ©. 



EC513201 

Wheel bearing (if necessary) 

1 . Remove: 
• Bearing © 

NOTE: 

Remove the bearing using a general bearing 
puller©. 



EC594000 

INSPECTION 

EC514100 

Wheel 

1. Measure: 
• Wheel runout 
Out of limit -^ Repair/replace. 




Wheel runout limit: 
Radial ©: 2.0 mm (0.08 in) 
Lateral ©: 2.0 mm (0.08 in) 



2. Inspect: 
• Bearing 
Rotate inner race with a finger. 
Rough spot/seizure -> Replace. 

NOTE: 



Replace the bearings, oil seal and wheel collar 
as a set. 



5-3 



FRONT WHEEL AND REAR WHEEL 



CHAS 



<$%) 





EC514200 

Wheel axle 

1. Measure: 

• Wheel axle bends 
Out of specification -^ Replace. 
Use the dial gauge ©. 




Wheel axle bending limit: 
0.5 mm (0.020 in) 



NOTE: 

The bending value is shown by one half of the 
dial gauge reading. 



A WARNING 



Do not attempt to straighten a bent axle. 



EC594200 

Brake disc 

1. Measure: 

• Brake disc deflection (only rear brake 
disc) 

Use the dial gauge ©. 
Out of specification -> Inspect wheel 
runout. 

If wheel runout is in good condition, 
replace the brake disc. 



^ 


Disc deflection limit: 




Standard 


<Limit> 


Rear 


— 


0.15 mm 
(0.006 in) 



Measure: 

• Brake disc thickness ® 
Out of limit -> Replace. 



^ 


Disc wear limit: 




Standard 


<Limit> 


Front 


3.0 mm (0.12 in) 


2.5 mm (0.10 in) 


Rear 


4.0 mm (0.16 in) 


3.5 mm (0.14 in) 



5-4 



FRONT WHEEL AND REAR WHEEL 



CHAS 



<$%) 




EC595000 

ASSEMBLY AND INSTALLATION 
Front wheel 

1. Install: 

• Bearing (left) © 

• Spacer © 

• Bearing (right) © 

• Oil seal E03 

NOTE: 

• Apply the lithium soap base grease on the 
bearing and oil seal lip when installing. 

• Use a socket that matches the outside diam- 
eter of the race of the bearing. 

• Left side of bearing shall be installed first. 

• Install the oil seal with its manufacture's 
marks or numbers facing outward. 

WMMMSSm 



Do not strike the inner race of the bearing. 
Contact should be made only with the outer 
race. 

2. Install: 

• Brake disc © 

• Bolt (brake disc) © 



l^™H. V 12 Nm (1 2 m • ka 8 7 ft • \b) 




NOTF- 



Tighten the bolts in stage, using a crisscross 
pattern. 




3. Install: 
• Collar © 

NOTE: 

• Apply the lithium soap base grease on the oil 
seal lip. 

• Install the collars with their projections ® 
facing the wheel. 



4. Install: 
• Wheel 

NOTE: 

Install the brake disc © between the brake 
pads © correctly. 



5-5 



FRONT WHEEL AND REAR WHEEL 



CHAS 



(fab 




5. Install: 

• Wheel axle © 

NOTE: 



Apply the lithium soap base grease on the 
wheel axle. 



6. Install: 

• Nut (wheel axle) © 



105 Nm (10.5 m • kg, 75 ft • lb) 



7. Tighten: 

• Bolt (axle holder) © 



23 Nm (2.3 m kg, 17 ft lb) 



NOTE: 

Before tightening the bolt, fit the wheel axle to 
the axle holder by stroking the front fork sev- 
eral times with the front brake applied. 



8. Install: 

• Brake hose © 



10 Nm (1.0 m -kg, 7.2 ft lb) 



To brake hose holder ©. 

NOTE: 

Before tightening the bolt (brake hose holder), 
align the top ® of the brake hose neck with the 
brake hose holder bottom ©. Then pass the 
brake hose in front of the axle boss © and fit it 
into the hose groove 0) so that the brake hose 
does not contact the nut (wheel axle). 



5-6 



FRONT WHEEL AND REAR WHEEL 



CHAS 



<$%) 




Install: 

• Hose cover © 

• Plain washer © 

• Bolt [hose cover (M8)] © 



16 Nm (1.6 m kg, 11 ft ■ lb) 



Bolt [hose cover (M6)] © 



7 Nm (0.7 m - kg, 5.1 ft ■ lb) 



Rear wheel 



1. Install: 

• Bearing (right) © 

• Circlip © Q^9 

• Spacer © 

• Bearing (left) © 



• Oil seal © 

NOTE: 

• Apply the lithium soap base grease on the 
bearing and oil seal lip when installing. 

• Install the bearing with seal facing outward. 

• Use a socket that matches the outside diam- 
eter of the race of the bearing. 

• Right side of bearing shall be installed first. 

• Install the oil seal with its manufacture's 
marks or numbers facing outward. 

CAUTION: 



Do not strike the inner race of the bearing. 
Contact should be made only with the outer 
race. 




2. Install: 

• Brake disc © 

• Bolt (brake disc) © 





l^™l— ■• IV 14 Nm (1 4 m ■ ka 1 ft • lb) 






NOTE: 





Tighten the bolts in stage, using a crisscross 
pattern. 



5-7 



FRONT WHEEL AND REAR WHEEL 



CHAS 



(fab 




3. Install: 

• Driven sprocket © 

• Bolt (driven sprocket) © 

• Plain washer (driven sprocket) © 

• Nut (driven sprocket) © 



42 Nm (4.2 m • kg, 30 ft • lb) 



NOTE: 

Tighten the nuts in stage, using a crisscross 
pattern. 

4. Install: 
• Collar © 

NOTE: 

Apply the lithium soap base grease on the oil 
seal lip. 



5. Install: 
• Wheel 

NOTE: 



Install the brake disc © between the brake 
pads © correctly. 



6. Install: 

• Drive chain © 

NOTE: 



Push the wheel © forward and install the drive 
chain. 



7. Install: 

• Chain puller (left) © 

• Wheel axle © 

NOTE: 

• Install the chain puller (left), and insert the 
wheel axle from left side. 

• Apply the lithium soap base grease on the 
wheel axle. 



5-8 



FRONT WHEEL AND REAR WHEEL 



CHAS 



(fab 




8. Install: 

• Chain puller (right) © 

• Plain washer © 

• Nut (wheel axle) © 



NOTE: 

Temporarily tighten the nut (wheel axle) at this 
point. 



9. Adjust: 

• Drive chain slack ® 




Drive chain slack: 
40 ~ 50 mm (1.6 ~ 2.0 in) 



Refer to "DRIVE CHAIN SLACK 
ADJUSTMENT" section in the CHAP- 
TER 3. 



10. Tighten: 

• Nut (wheel axle) © 



125 Nm (12.5 m kg, 90 ft lb) 



Locknut © 



16 Nm (1.6 m kg, 11 ft • lb) 



5-9 



FRONT BRAKE AND REAR BRAKE 



CHAS 



<$%) 



EC5A0000 

FRONT BRAKE AND REAR BRAKE 

EC5A8000 

FRONT BRAKE 



6 Nm (0.6 m • kg, 4.3 ft • lb) 




30 Nm (3.0 m • kg, 22 ft • lb) 



Extent of removal: 




© Brake hose removal 
(3) Master cylinder removal 




© Caliper removal 


Extent of removal 


Order 


Part name 


Q'ty 


Remarks 


Preparation for removal 




FRONT BRAKE REMOVAL 

Hold the machine by placing the 
suitable stand under the engine. 
Drain the brake fluid. 




wwmmu* 


Support the machine securely so there is no 
danger of it falling over. 


Refer to "REMOVAL POINTS". 






1 


Hose cover 


1 






2 


Brake hose holder 


1 




c 


) 


| ©| 


3 
4 


Bolt (brake hose holder) 
Union bolt 


2 
2 


Only loosening. 








5 


Brake hose 


1 




a 


D 

t 


6 
7 
8 
9 


Pad pin plug 
Pad pin 
Caliper 
Brake lever 


1 
1 
1 
1 


Remove when loosening the pad pin. 
Loosen when disassembling the caliper. 


I 


10 
11 


Master cylinder bracket 
Master cylinder 


1 
1 





5-10 



FRONT BRAKE AND REAR BRAKE 



CHAS 



<$%) 



EC5A8100 

REAR BRAKE 



30 Nm (3.0 m • kg, 22 ft - lb) 



1 Nm (0.1 m - kg, 0.7 ft • lb) 



30 Nm (3.0 m • kg, 22 ft » lb) 4 



3 Nm (0.3 m • kg, 2.2 ft - lb) 



18 Nm (1.8 m -kg, 13 ft -lb) 




7 Nm (0.7 m - kg, 5.1 ft • lb) 



Extent of removal: 



© Master cylinder removal 
® Caliper removal 



i Brake hose removal 



Extent of removal 


Order 


Part name 


Q'ty 


Remarks 


Preparation for removal 




REAR BRAKE REMOVAL 

Hold the machine by placing the 
suitable stand under the engine. 

Rear wheel 

Drain the brake fluid. 




wmmzuma 


Support the machine securely so there is no 
danger of it falling over. 


Refer to "FRONT WHEEL AND REAR 

WHEEL" section. 

Refer to "REMOVAL POINTS". 


4 

i 
©I © ©J 

© 

I 


1 
2 
3 
4 
5 
6 
7 
8 


Brake pedal 
Master cylinder 
Brake hose holder 
Union bolt 
Brake hose 
Pad pin plug 
Pad pin 
Caliper 


1 
1 
2 
2 

1 
1 
1 
1 


Remove when loosening the pad pin. 
Loosen when disassembling the caliper. 



5-11 



FRONT BRAKE AND REAR BRAKE 



CHAS 



(fab 



EC5A8200 

CALIPER DISASSEMBLY 



3 Nm (0.3 m • kg, 2.2 ft • lb) 



18 Nm (1.8 m -kg, 13 ft -lb) 
T 



6 Nm (0.6 m • kg, 4.3 ft • lb) ^ 




18 Nm (1.8 m -kg, 13 ft -lb) 



3 Nm (0.3 m • kg, 2.2 ft - lb) 



\M Front 
1] Rear 



Extent of removal 






© Front caliper disassembly 






© Rear caliper disassembly 


Extent of removal 


Order 


Part name 


Q'ty 


Remarks 




© 
© 
© 
© 
© 
© 


CALIPER DISASSEMBLY 

Pad pin 
Brake pad 
Pad support 
Caliper piston 
Dust seal 
Piston seal 


A 


B 


Refer to "REMOVAL POINTS". 
\ Refer to "REMOVAL POINTS". 


c 


) Q 


D 


1 
2 
1 
2 
2 
2 


1 
2 

1 
1 
1 
1 



5-12 



FRONT BRAKE AND REAR BRAKE 



CHAS 



(fab 



EC5A8300 

MASTER CYLINDER DISASSEMBLY 



2 Nm (0.2 m -kg, 1.4 ft -lb) 



2 Nm (0.2 m -kg, 1.4 ft -lb) 




\M Front 
1] Rear 
Extent of removal: 



© Front master cylinder disassembly © Rear master cylinder disassembly 



Extent of removal 


Order 


Part name 


Q'ty 


Remarks 






MASTER CYLINDER DISAS- 










SEMBLY 












© 
© 


Master cylinder cap 
Diaphragm 






© T 


© 


Master cylinder boot 








I 


© 


Circlip 




Use a long nose circlip pliers. 






© 


Plain washer 






©I 4 


© 


Push rod 






© 


Master cylinder kit 







5-13 



FRONT BRAKE AND REAR BRAKE 



CHAS 



<$%) 




EC5A3000 

REMOVAL POINTS 
Brake fluid 

1 . Remove: 
[Front] 

• Master cylinder cap © 
[Rear] 

• Master cylinder cap © 

• Protector 

NOTE: 



Do not remove the diaphragm. 



S Front 
1] Rear 



2. Connect the transparent hose © to the 
bleed screw © and place a suitable con- 
tainer under its end. 

\M Front 
1] Rear 

3. Loosen the bleed screw and drain the 
brake fluid while pulling the lever in or 
pushing down on the pedal. 

CAU 



• Do not reuse the drained brake fluid. 

• Brake fluid may erode painted surfaces or 
plastic parts. Always clean up spilled 
fluid immediately. 

EC533301 

Caliper piston 

1 . Remove: 

• Caliper piston 
Use compressed air and proceed care- 
fully. 



A WARNING 



• Cover piston with rag and use extreme 
caution when expelling piston from cylin- 
der. 

• Never attempt to pry out piston. 



Caliper piston removal steps: 

• Insert a piece of rag into the caliper to lock 
one caliper. 

• Carefully force the piston out of the caliper 
cylinder with compressed air. 



\E\ Front 
1] Rear 



5-14 



FRONT BRAKE AND REAR BRAKE 



CHAS 



<$%) 



w 




B| 






V 


^r^\ 






EC533402 

Piston seal kit 

1 . Remove: 

• Dust seal © 

• Piston seal © 

NOTE: 

Remove the piston seals and dust seals by 
pushing them with a finger. 

CAUTION: 



Never attempt to pry out piston seals and 
dust seals. 



A WARNING 



Replace the piston seals and dust seals 
whenever a caliper is disassembled. 

\E Front 
1] Rear 



EC5A4000 

INSPECTION 

EC534112 

Master cylinder 

1. Inspect: 

• Master cylinder inner surface ® 
Wear/scratches -> Replace master cyl- 
inder assembly. 
Stains -> Clean. 



A WARNING 



Use only new brake fluid. 



S Front 
1] Rear 

2. Inspect: 

• Diaphragm © 
Crack/damage -> Replace. 
\M Front 
1] Rear 



3. Inspect: 

• Master cylinder piston © 

• Master cylinder cup © 
Wear/damage/score marks -» Replace 
master cylinder kit. 

\M Front 
1] Rear 



5-15 



FRONT BRAKE AND REAR BRAKE 



CHAS 



<$%) 




EC534214 

Caliper 

1. Inspect: 

• Caliper cylinder inner surface ® 
Wear/score marks -» Replace caliper 
assembly. 
\M Front 
1] Rear 



2. Inspect: 

• Caliper piston © 
Wear/score marks -» Replace caliper 
piston assembly. 



A WARNING 



Replace the piston seals and dust seals 
whenever a caliper is disassembled. 



Brake hose 

1. Inspect: 

• Brake hose © 
Crack/damage -» Replace. 



EC5A5000 

ASSEMBLY AND INSTALLATION 



A WARNING 



• All internal parts should be cleaned in 
new brake fluid only. 

• Internal parts should be lubricated with 
brake fluid when installed. 

• Replace the piston seals and dust seals 
whenever a caliper is disassembled. 

EC5A5800 

Caliper piston 

1. Clean: 

• Caliper 

• Piston seal 

• Dust seal 

• Caliper piston 

Clean them with brake fluid. 



5-16 



FRONT BRAKE AND REAR BRAKE 



CHAS 



<$%) 




2. Install: 

• Piston seal © 

• Dust seal © 



A WARNING 



Always use new piston seals and dust 
seals. 

NOTE: 

Fit the piston seals and dust seals onto the slot 
on caliper correctly. 

\M Front 
1] Rear 



3. Install: 

• Caliper piston © 

NOTE: 



Apply the brake fluid on the piston wall. 

CAUTON; 

• Install the piston with its shallow 
depressed side ® facing the caliper. 

• Never force to insert. 

\M Front 
1] Rear 



EC5A5700 

Front caliper 

1. Install: 

• Pad support © 

• Brake pad © 

• Pad pin © 

NOTE: 

• Install the brake pads with their projections 
® into the caliper recesses ©. 

• Temporarily tighten the pad pin at this point. 



5-17 



FRONT BRAKE AND REAR BRAKE 



CHAS 



<$%) 




2. Install: 

• Copper washer © 

• Union bolt © 



30 Nm (3.0 m • kg, 22 ft • lb) 



A WARNING 



Always use new copper washers. 



liiO^ 



Install the brake hose so that its pipe por- 
tion ® directs as shown and lightly 
touches the projection © on the caliper. 



3. Install: 

• Brake hose holder © 

• Caliper© 

• Bolt (caliper) © 



23 Nm (2.3 m kg, 17 ft lb) 



NOTE: 

Fit the brake hose holder cut ® over the pro- 
jection (b) on the front fork and clamp the brake 
hose. 

4. Tighten: 
• Pad pin © 



18 Nm (1.8 m -kg, 13 ft -lb) 



5. Install: 

• Pad pin plug © 



3 Nm (0.3 m ■ kg, 2.2 ft • lb) 




EC5A5100 

Rear caliper 

1. Install: 

• Pad support © 

• Brake pad © 

• Pad pin © 

NOTE: 

• Install the brake pads with their projections 
® into the caliper recesses ©. 

• Temporarily tighten the pad pin at this point. 



5-18 



FRONT BRAKE AND REAR BRAKE 



CHAS 



<$%) 




2. Install: 

• Disc cover © 

• Bolt (disc cover) © 



7 Nm (0.7 m ■ kg, 5.1 ft ■ lb) 



3. Install: 

• Caliper© 

• Rear wheel © 

Refer to "FRONT WHEEL AND REAR 
WHEEL" section. 

4. Tighten: 

• Pad pin © 





pin 


\ 18 Nm (1.8 m 


•kg 


,13ft 


•lb) 


. Install: 
• Pad 


plug® 










|\ 3Nm(0.3m- 


kg, 


2.2 ft • 


lb) 



Master cylinder kit 

1. Clean: 

• Master cylinder 

• Master cylinder kit 

Clean them with brake fluid. 




2. Install: 

• Master cylinder cup (primary) © 

• Master cylinder cup (secondary) © 
To master cylinder piston ©. 

NOTE: 

Apply the brake fluid on the master cylinder 
cup. 



A WARNING 



After installing, cylinder cup should be 
installed as shown direction. Wrong instal- 
lation cause improper brake performance. 

Front 
HI Rear 



5-19 



FRONT BRAKE AND REAR BRAKE 



CHAS 



(fab 




3. Install: 
• Spring © 
To master cylinder piston ©. 

NOTE: 

Install the spring at the smaller dia. side. 

\M Front 
1] Rear 



4. Install: 
[Front] 

• Master cylinder kit © 

• Plain washer © 

• Circlip © 

• Master cylinder boot © 
To master cylinder ©. 

[Rear] 

• Master cylinder kit © 

• Push rod © 

• Circlip © 

• Master cylinder boot © 
To master cylinder ®. 

NOTE: 

• Apply the brake fluid on the master cylinder 
kit. 

• Apply the lithium soap base grease on the tip 
of the push rod. 

• When installing the circlip, use a long nose 
circlip pliers. 

S Front 
1] Rear 




EC5A5310 

Front master cylinder 

1. Install: 

• Master cylinder © 

• Master cylinder bracket © 

• Bolt (master cylinder bracket) © 



9 Nm (0.9 m ■ kg, 6.5 ft • lb) 



NOTE: 

• Install the bracket so that the arrow mark ® 
face upward. 

• First tighten the bolts on the upper side of the 
master cylinder bracket, and then tighten the 
bolts on the lower side. 



5-20 



FRONT BRAKE AND REAR BRAKE 



CHAS 



<$%) 




2. Install: 

• Brake lever © 

• Bolt (brake lever) © 



|\ 6Nm(0.6m 


- kg, 4.3 ft 


•lb) 


• Nut (brake lever) © 


\ 6 Nm (0.6 m 


- kg, 4.3 ft 


•lb) 


NOTF- 


Apply the lithium soap base grease on the 
brake lever sliding surface, bolt and contacting 
surface of the master cylinder piston. 



Rear master cylinder 

1. Install: 

• Copper washer © 

• Brake hose © 

• Union bolt © 



30 Nm (3.0 m • kg, 22 ft • lb) 



A WARNING 



Always use new copper washers. 



MMEM3 



Install the brake hose so that its pipe por- 
tion (a) directs as shown and lightly 
touches the projection © on the master 
cylinder. 



2. Install: 

• Master cylinder © 

• Bolt (master cylinder) © 



11 Nm(1.1 m • kg, 8.0 ft - lb) 



Install: 

• Spring © 

• Brake pedal © 

• O-ring © CH3 

• Bolt (brake pedal) © 



26 Nm (2.6 m -kg, 19 ft lb) 



• Clip© 

NOTE: 

• Apply the lithium soap base grease on the 
bolt, O-ring and brake pedal bracket. 

• Install the clip with its stopper portion ® fac- 
ing inward. 



5-21 



FRONT BRAKE AND REAR BRAKE 



CHAS 



(fab 




4. Install: 

• Pin© 

• Plain washer © 

• Cotter pin © 



NOTE: 

After installing, check the brake pedal height. 
Refer to "REAR BRAKE ADJUSTMENT" sec- 
tion in the CHAPTER 3. 



Front brake hose 

1. Install: 

• Brake hose © 



10 Nm (1.0 m kg, 7.2 ft lb) 



To brake hose holder ©. 

NOTE: 

Before tightening the bolt (brake hose holder), 
align the top ® of the brake hose neck with the 
brake hose holder bottom ©. Then pass the 
brake hose in front of the axle boss © and fit it 
into the hose groove 0) so that the brake hose 
does not contact the nut (wheel axle). 




2. Install: 

• Hose cover © 

• Plain washer © 

• Bolt [hose cover (M8)] © 



16 Nm (1.6 m kg, 11 ft • lb) 



Bolt [hose cover (M6)] © 



7 Nm (0.7 m • kg, 5.1 ft • lb) 



3. Pass the brake hose through the cable 
guide ©, then through the guide ® on 
the protector ©. 



5-22 



FRONT BRAKE AND REAR BRAKE 



CHAS 



<$%) 




Install: 

• Copper washer © 

• Brake hose © 

• Union bolt (3) 



30 Nm (3.0 m ■ kg, 22 ft ■ lb) 







-Hi) 


/ \ _____ 




eij^i^ 


^6)^ 



A WARNING 



Always use new copper washers. 

CAUTION: 

Install the brake hose so that its pipe por- 
tion ® directs as shown and lightly 
touches the projection (b) on the master 
cylinder. 




Rear brake hose 

1. Install: 

• Copper washer © 

• Brake hose © 

• Union bolt © 



30 Nm (3.0 m ■ kg, 22 ft ■ lb) 



A WARNING 



Always use new copper washers. 



wmimsM!: 



Install the brake hose so that its pipe por- 
tion ® directs as shown and lightly 
touches the projection © on the caliper. 



5-23 



FRONT BRAKE AND REAR BRAKE 



CHAS 



<$%) 





2. Install: 

• Brake hose holder © 

• Screw (brake hose holder) 



1 Nm (0.1 m . kg, 0.7 ft ■ lb) 



II 

After installing the brake hose holders, 
make sure the brake hose does not contact 
the spring (rear shock absorber). If it does, 
correct its twist. 



Brake fluid 

1. Fill: 

• Brake fluid 
Until the fluid level reaches "LOWER" 
level line (a). 



<o 



Recommended brake fluid: 
DOT #4 



A WARNING 



• Use only the designated quality brake 
fluid: 

otherwise, the rubber seals may deterio- 
rate, causing leakage and poor brake per- 
formance. 

• Refill with the same type of brake fluid; 
mixing fluids may result in a harmful chem- 
ical reaction and lead to poor performance. 

• Be careful that water does not enter the 
master cylinder when refilling. Water will 
significantly lower the boiling point of the 
fluid and may result in vapor lock. 





Brake fluid may erode painted surfaces or 
plastic parts. Always clean up spilled fluid 
immediately. 

\E Front 
1] Rear 



5-24 



FRONT BRAKE AND REAR BRAKE 



CHAS 



<$%) 



2. Air bleed: 
• Brake system 
Refer to "BRAKE SYSTEM AIR 
BLEEDING" section in the CHAPTER 
3. 



3. Inspect: 

• Brake fluid level 
Fluid at lower level -> Fill up. 
Refer to "BRAKE FLUID LEVEL 
INSPECTION" section in the CHAP- 
TERS. 




4. Install: 
[Front] 

• Diaphragm 

• Master cylinder cap © 

• Screw (master cylinder cap) 



2 Nm (0.2 m kg, 1.4 ft lb) 



[Rear] 

• Diaphragm 

• Master cylinder cap © 

• Bolt (master cylinder cap) © 



2 Nm (0.2 m kg, 1.4 ft lb) 



mmmmm 



After installation, while pulling the lever in 
or pushing down on the pedal, check 
whether there is any brake fluid leaking 
where the union bolts are installed respec- 
tively at the master cylinder and caliper. 

\M Front 
1] Rear 
5. Install: (rear brake only) 

• Protector © 

• Bolt (protector) © 



7 Nm (0.7 m ■ kg, 5.1 ft ■ lb) 



5-25 



FRONT FORK 



CHAS 



<$%) 



EC550000 

FRONT FORK 




23 Nm (2.3 m -kg, 17 ft- lb) 



10 Nm (1.0 m -kg, 7.2 ft -lb) 



10 Nm (1.0 m -kg, 7.2 ft -lb) 



Extent of removal: 




© Front fork removal 






Extent of removal 


Order 


Part name 


Q'ty 


Remarks 


Preparation for removal 




FRONT FORK REMOVAL 

Hold the machine by placing the 
suitable stand under the engine. 

Front wheel 

Front caliper 

Number plate 
Handlebar 




rmvAUJiLVd 


Support the machine securely so there is no 
danger of it falling over. 


Refer to "FRONT WHEEL AND REAR 
WHEEL" section. 

Refer to "FRONT BRAKE AND REAR 
BRAKE" section. 

Refer to "HANDLEBAR" section. 


c 


) 


1 
2 
3 
4 
5 
6 


Protector 

Brake hose holder 

Pinch bolt (handle crown) 

Cap bolt 

Pinch bolt (under bracket) 

Front fork 


1 
2 
2 
1 
2 
1 


Only loosening. 

Loosen when disassembling the front fork. 

Only loosening. 



5-26 



FRONT FORK 



CHAS 



(fab 



EC558000 

FRONT FORK DISASSEMBLY 



29 Nm (2.9 m • kg, 21 ft * lb) 



1 Nm (0.1 m - kg, 0.7 ft • lb) 




Extent of removal: 






© Oil seal removal 




© Damper rod removal 


Extent of removal 


Order 


Part name 


Q'ty 


Remarks 






FRONT FORK DISASSEMBLY 












© 
© 
© 
© 


Cap bolt 
Fork spring 
Dust seal 
Stopper ring 




Refer to "REMOVAL POINTS". 
Drain the fork oil. 

- Refer to "REMOVAL POINTS". 


c 


) 




© 


Inner tube 






V. 




© 


Outer tube 








a 


k 


© 


Piston metal 








-j 


© 


Slide metal 












© 


Plain washer 












® 


Oil seal 










® 


Spring guide 










© 


Base valve 




-i Use special tool. 

-J" Refer to "REMOVAL POINTS". 


. 




© 


Damper rod 





5-27 



FRONT FORK 



CHAS 



<$%) 



EC556000 

HANDLING NOTE 
NOTE: 



The front fork requires careful attention. So it is 
recommended that the front fork be main- 
tained at the dealers. 



wm 

To prevent an accidental explosion of air, 
the following instructions should be 
observed: 

• The front fork with a built-in piston rod 
has a very sophisticated internal con- 
struction and is particularly sensitive to 
foreign material. 

Use enough care not to allow any foreign 
material to come in when the oil is 
replaced or when the front fork is disas- 
sembled and reassembled. 

• Before removing the cap bolts or front 
forks, be sure to extract the air from the 
air chamber completely. 





/ A 


^XD 




EC553000 

REMOVAL POINTS 

EC553150 

Cap bolt 

1 . Remove: 

• Cap bolt © 

From the outer tube. 

NOTE: 

Before removing the front fork from the 
machine, loosen the cap bolt. 

2. Remove: 

• Cap bolt © 

NOTE: 

• While compressing the fork spring, set the 
thin type spanners © between the spacer © 
and spring guide ©. 

• Hold the locknut ® and remove the cap bolt. 



5-28 



FRONT FORK 



CHAS 



<$%) 






\cX 


(7) 


rxz£§\- 


\^x 


\^~ J 


(D^- 


-►© 






EC553201 

Inner tube 



1. 



Remove: 

• Dust seal © 

• Stopper ring ® 



Using slotted-head screwdriver. 



CAUTION: 

Take care not to scratch the inner tube. 

2. Remove: 
• Inner tube © 



Oil seal removal steps: 

• Push in slowly ® the inner tube just before 
it bottoms out and then pull it back quickly 
©■ 

• Repeat this step until the inner tube can 
be pulled out from the outer tube. 



EC55331 1 

Damper rod 

1 . Remove: 

• Base valve © 

• Damper rod ® 

NOTE: 



Use a damper rod holder < 
rod. 



to lock the damper 



/- 



Damper rod holder: 
YM-1 423/90890-01 423 



EC554000 

INSPECTION 

EC554100 

Damper rod 

1. Inspect: 

• Damper rod © 
Bend/damage -> Replace damper rod. 

CAUTION: 

The front fork with a built-in piston rod has 
a very sophisticated internal construction 
and is particularly sensitive to foreign 
material. 

Use enough care not to allow any foreign 
material to come in when the oil is replaced 
or when the front fork is disassembled and 
reassembled. 



5-29 



FRONT FORK 



CHAS 



<$%) 




EC554200 

Base valve 

1. Inspect: 

• Valve assembly © 
Wear/damage -» Replace. 

• O-ring (2) 
Damage -> Replace. 



EC554400 

Fork spring 

1. Measure: 

• Fork spring free length ® 
Out of specification -> Replace. 



^ 


Fork spring free length: 


Standard 


Limit 


460 mm (18.1 in) 


455 mm (17.9 in) 



EC554502 

Inner tube 

1. Inspect: 

• Inner tube surface ® 

Score marks -> Repair or replace. 
Use #1 ,000 grit wet sandpaper. 
Damaged oil lock piece -> Replace. 

• Inner tube bends 

Out of specification -^ Replace. 
Use the dial gauge ©. 




Inner tube bending limit: 
0.2 mm (0.008 in) 



NOTE: 

The bending value is shown by one half of the 
dial gauge reading. 




A WARNING 



Do not attempt to straighten a bent inner 
tube as this may dangerously weaken the 
tube. 

EC554600 

Outer tube 

1. Inspect: 

• Outer tube © 
Score marks/wear/damage -» Replace. 



5-30 



FRONT FORK 



CHAS 



<$%) 




EC554700 



Cap bolt 

1. Inspect: 

• Cap bolt © 

• O-ring © 

• Air bleed screw (3) 
Wear/damage -^ Replace. 



EC555000 

ASSEMBLY AND INSTALLATION 
Front fork assembly 

1 . Wash the all parts in a clean solvent. 




© 



rnni. 



\^i 



UUUs J 



I 



2. Install: 

• Damper rod © 
To inner tube (2 

CAUTION: 



To install the damper rod into the inner 
tube, hold the inner tube aslant. If the inner 
tube is held vertically, the damper rod may 
fall into it, damaging the valve inside. 



3. Install: 

• Copper washer © 

• O-ring © 

• Base valve © 
To inner tube @. 



4. Tighten: 

• Base valve © 



55 Nm (5.5 m ■ kg, 40 ft ■ lb) 



NOTE: 

• Use a damper rod holder © to lock the 
damper rod ©. 

• Apply the LOCTITE® on the base valve 
thread. 



/- 



Damper rod holder: 
YM-1 423/90890-01 423 



5-31 



FRONT FORK 



CHAS 



(fab 






5. Install: 

• Spring guide © 

• Locknut (2) 

To damper rod (3). 

NOTE: 

• Install the spring guide with its cut ® facing 
upward. 

• With its thread © facing upward, fully finger 
tighten the locknut onto the damper rod. 

6. Install: 

• Dust seal © 

• Stopper ring © 

• Oil seal © 

• Plain washer @ 

• Slide metal ® 
To inner tube ©. 

NOTE: 

• Apply the fork oil on the inner tube. 

• When installing the oil seal, use vinyl seat ® 
with fork oil applied to protect the oil seal lip. 

• Install the oil seal with its manufacture's 
marks or number facing the axle holder side. 



7. Install: 

• Piston metal © E^3 

NOTE: 



Install the piston metal onto the slot on inner 
tube. 



8. Install: 

• Outer tube © 
To inner tube ( 



5-32 



FRONT FORK 



CHAS 



(fab 




9. Install: 

• Slide metal © 

• Plain washer ® 
To outer tube slot. 

NOTE: 

Press the slide metal into the outer tube with 
fork seal driver (3). 



/> 



Fork seal driver: 
YM-01 442/90890-01 442 



10. Install: 
• Oil seal © 

NOTE: 



Press the oil seal into the outer tube with fork 
seal driver (2). 



^ 



Fork seal driver: 
YM-01 442/90890-01 442 



11. Install: 

• Stopper ring © 

NOTE: 



Fit the stopper ring correctly in the groove in 
the outer tube. 



12. Install: 

• Dust seal © 

NOTE: 



Apply the lithium soap base grease on the 
inner tube. 



5-33 



FRONT FORK 



CHAS 



<$%) 




13. Check: 

• Inner tube smooth movement 
Tightness/binding/rough spots -> 
Repeat the steps 2 to 12. 





© 

V > 





14. Compress the front fork fully. 

15. Fill: 

• Front fork oil 
Until outer tube top surface with recom- 
mended fork oil ©. 



*o 



Recommended oil: 
Suspension oil "01" 



||§ 

• Be sure to use recommended fork oil. If 
other oils are used, they may have an 
excessively adverse effect on the front 
fork performance. 

• Never allow foreign materials to enter the 
front fork. 




16. After filling, pump the damper rod © 
slowly up and down more than 10 times 
to distribute the fork oil. 

17. Fill: 

• Front fork oil 
Until outer tube top surface with recom- 
mended fork oil once more. 



1 8. After filling, pump the outer tube © slowly 
up and down (about 200 mm (7.9 in) 
stroke) to distribute the fork oil once 
more. 

NOTE: 

Be careful not to excessive full stroke. A stroke 
of 200 mm (7.9 in) or more will cause air to 
enter. In this case, repeat the steps 15 to 18. 



5-34 



FRONT FORK 



CHAS 



<$%) 



19. Wait ten minutes until the air bubbles 
have been removed from the front fork, 
and the oil has dispense evenly in system 
before setting recommended oil level. 

NOTE: 

Fill with the fork oil up to the top end of the 
outer tube, or the fork oil will not spread over to 
every part of the front forks, thus making it 
impossible to obtain the correct level. 
Be sure to fill with the fork oil up to the top of 
the outer tube and bleed the front forks. 



n *r^ 




©k^ 


r ® 




„ . 


f 












i 


311404 


r 





20. Measure: 

• Oil level (left and right) ® 
Out of specification -> Adjust. 




Standard oil level: 
135 mm (5.31 in) 

Extent of adjustment: 
80 -150 mm (3.15-5.91 in) 
From top of outer tube with 
inner tube and damper rod © 
fully compressed without 
spring. 



NOTE: 

Be sure to install the spring guide ® when 
checking the oil level. 



A WARNING 



Never fail to make the oil level adjustment 
between the maximum and minimum level 
and always adjust each front fork to the 
same setting. Uneven adjustment can 
cause poor handling and loss of stability. 



5-35 



FRONT FORK 



CHAS 



(fab 



(T) 


^t 


1 
1 


® 

< 


\U 


(zr^ 




Sj 






u 







21. Measure: 
• Distance ® 
Out of specification -> Turn into the 
locknut. 




Distance ®: 
20 mm (0.79 in) or more 
Between damper rod © top and 
locknut © top. 




22. Loosen: 

• Rebound damping adjuster © 

NOTE: 



• Loosen the rebound damping adjuster finger 
tight. 

• Record the set position of the adjuster (the 
amount of turning out the fully turned in posi- 
tion). 

23. Install 

• Cushion rubber © 

• Washer © 

• Spacer © 

To cap bolt @. 

NOTE: 

Install the cushion rubber with its smaller 
dia.end ® facing the cap bolt. 



24. Install: 

• Push rod © 

• Fork spring © 

NOTE: 

• Install the fork spring with the damper rod © 
pulled up. 

• After installing the fork spring, hold the 
damper rod end so that it will not go down. 



25. Install: 

• Cap bolt © 
Fully tighten the cap bolt onto the 
damper rod by hand. 



5-36 



FRONT FORK 



CHAS 



(fab 





26. Tighten: 

• Cap bolt (locknut) © 



29 Nm (2.9 m • kg, 21 ft • lb) 





/ A 


^XD 



NOTE: 

• While compressing the fork spring, set the 
thin type spanners © between the spacer © 
and spring guide ©. 

• Hold the locknut © and tighten the cap bolt 
with specified torque. 

27. Install: 

• Cap bolt © 
To outer tube. 

NOTE: 

Temporarily tighten the cap bolt. 



28. Install: 

• Protector guide © 





Installation 

1. Install: 

• Front fork © 

NOTE: 

• Temporarily tighten the pinch bolts (under 
bracket). 

• Do not tighten the pinch bolts (handle crown) 
yet. 

2. Tighten: 

• Cap bolt © 



30 Nm (3.0 m • kg, 22 ft • lb) 



3. Adjust: 

• Front fork top end ® 




Front fork top end (standard) ® 
Zero mm (Zero in) 



5-37 



FRONT FORK 



CHAS 



<$%) 





Gx 


WM^x 






//\r 






d) 


n£\°/*/ j 


riSZ^ 










4. Tighten: 

• Pinch bolt (handle crown) © 



23 Nm (2.3 m kg, 17 ft lb) 



Pinch bolt (under bracket) © 



20 Nm (2.0 m kg, 14 ft lb) 



Tighten the under bracket to specified 
torque. If torqued too much, it may cause 
the front fork to malfunction. 

5. Install: 

• Brake hose holder © 

• Caliper© 

• Bolt (caliper) © 



23 Nm (2.3 m -kg, 17 ft lb) 



NOTE: 

Fit the brake hose holder cut ® over the pro- 
jection © on the front fork and clamp the brake 
hose. 

6. Install: 

• Brake hose holder © 

• Bolt (brake hose holder) © 



10 Nm (1.0 m -kg, 7.2 ft -lb) 



• Protector © 

• Bolt (protector) © 



10 Nm (1.0 m -kg, 7.2 ft -lb) 



NOTE: 

When installing the brake hose holder, align 
the top ® of the brake hose neck with the 
brake hose holder bottom ©. Then pass the 
brake hose © in front of the axle boss © and 
fit it into the hose groove 0) so that the brake 
hose does not contact the nut (wheel axle). 




7. Adjust: 

• Rebound damping force 

NOTE: 



Turn in the damping adjuster © finger-tight 
and then turn out to the originally set position. 



5-38 



HANDLEBAR 



CHAS 



(fab 



EC5B0000 

HANDLEBAR 



4 Nm (0.4 m • kg, 2.9 ft - lb) 



9 Nm (0.9 m * kg, 6.5 ft « lb) 



4 Nm (0.4 m • kg, 2.9 ft - lb) 




Nm (0.2 m -kg, 1.4 ft -lb) 



Extent of removal: 




© Handlebar removal 






Extent of removal 


Order 


Part name 


Q'ty 


Remarks 






HANDLEBAR REMOVAL 






Preparation for removal 




Number plate 




Remove the clamp portion only. 






1 
2 


Hot starter cable 

Hot starter lever holder 




Disconnect at the lever side. 






3 


Clutch cable 




Disconnect at the lever side. 






4 


Clutch lever holder 










5 


"ENGINE STOP" button 










6 


Master cylinder 




Refer to "REMOVAL POINTS". 






7 


Throttle cable cap 









) 


8 


Throttle cable #2 (pushed) 




Disconnect at the throttle side. 


K 


9 


Throttle cable #1 (pulled) 




Disconnect at the throttle side. 






10 


Grip (right) 




Refer to "REMOVAL POINTS". 






11 


Tube guide 










12 


Cover (grip cap) 










13 


Collar 










14 


Grip (left) 




Refer to "REMOVAL POINTS". 






15 


Handlebar holder (upper) 


2 








16 


Handlebar 


1 





5-39 



HANDLEBAR 



CHAS 



<$%) 




EC5B3000 

REMOVAL POINTS 

EC5B3100 

Master cylinder 

1 . Remove: 

• Master cylinder bracket © 

• Master cylinder ® 

CAUTION; 

• Do not let the master cylinder hang on the 
brake hose. 

• Keep the master cylinder cap side hori- 
zontal to prevent air from coming in. 




EC5B3200 

Grip 

1 . Remove: 
• Grip © 

NOTE: 



Blow in air between the handlebar or tube 
guide and the grip. Then remove the grip 
which has become loose. 



EC5B4000 

INSPECTION 

EC5B4100 

Handlebar 

1. Inspect: 

• Handlebar © 
Bends/cracks/damage -» Replace. 



A WARNING 



Do not attempt to straighten a bent handle- 
bar as this may dangerously weaken the 
handlebar. 



5-40 



HANDLEBAR 



CHAS 



<$%) 




EC5B5000 

ASSEMBLY AND INSTALLATION 
Handlebar 

1. Install: 

• Handlebar © 

• Handlebar holder © 

• Bolt (handlebar holder) © 



28 Nm (2.8 m ■ kg, 20 ft • lb) 



NOTE: 

• The upper 



handlebar holder should be 
installed with the punched mark ® forward. 
• First tighten the bolts on the front side of the 
handlebar holder, and then tighten the bolts 
on the rear side. 



2. Install: 

• Grip (left) © 



Apply the adhesive to the handlebar ©. 

NOTE: 

• Before applying the adhesive, wipe off 
grease or oil on the handlebar surface ® 
with a lacquer thinner. 

• Install the grip (left) to the handlebar so that 
the line (b) between the two arrow marks 
faces straight upward. 

3. Install: 

• Grip (right) © 

• Collar © 

Apply the adhesive on the tube guide 

©■ 

NOTE: 

• Before applying the adhesive, wipe off 
grease or oil on the tube guide surface ® 
with a lacquer thinner. 

• Install the grip to the tube guide so that the 
grip match mark © and tube guide slot © 
form the angle as shown. 



5-41 



HANDLEBAR 



CHAS 



<$%) 




4. Install: 

• Collar © 

• Cover (grip cap) © 

• Throttle grip (3) 

NOTE: 

Apply the lithium soap base grease on the 
throttle grip sliding surface. 



5. Install: 

• Throttle cables © 
To tube guide ©. 

NOTE: 

Apply the lithium soap base grease on the 
throttle cable end and tube guide cable wind- 
ing portion. 



6. Install: 

• Throttle cable cap © 

• Screw (throttle cable cap) © 



4 Nm (0.4 m • kg, 2.9 ft • lb) 



A WARNING 



After tightening the screws, check that the 
throttle grip © moves smoothly. If it does 
not, retighten the bolts for adjustment. 



7. Install: 

• Cover (grip cap) © 



Cover (throttle cable cap) © 



5-42 



HANDLEBAR 



CHAS 



(fab 




8. Install: 

• Master cylinder © 

• Master cylinder bracket © 

• Bolt (master cylinder bracket) © 



9 Nm (0.9 m ■ kg, 6.5 ft • lb) 



NOTE: 

• Install the bracket so that the arrow mark ® 
faces upward. 

• First tighten the bolt on the upper side of the 
master cylinder bracket, and then tighten the 
bolt on the lower side. 

9. Install: 

• "ENGINE STOP" button © 

• Clutch lever holder © 

• Bolt (clutch lever holder) © 



IX 4 Nm (0.4 m. kg, 


2.9 ft 


lb) 


• Hot starter lever holder © 

• Bolt (hot starter lever holder) © 


IX 4 Nm (0.4 m. kg, 


2.9 ft 


lb) 


• Clamp © 

MHTF- 



• The "ENGINE STOP" button, clutch lever 
holder and clamp should be installed accord- 
ing to the dimensions shown. 

• Pass the "ENGINE STOP" button lead in the 
middle of the clutch lever holder. 



10. Install: 

• Clutch cable © 

• Hot starter cable © 

NOTE: 

Apply the lithium soap base grease on the 
clutch cable end and hot starter cable end. 

11. Adjust: 

• Clutch lever free play 

Refer to "CLUTCH ADJUSTMENT" 
section in the CHAPTER 3. 

• Hot starter lever free play 

Refer to "HOT STARTER LEVER 
ADJUSTMENT" section in the CHAP- 
TER 3. 



5-43 



HANDLEBAR 



CHAS 



(fab 




12. Clamp the clamp portion ® of the num- 
ber plate to the handlebar. 

1 3. Insert the end of the fuel breather hose © 
into the hole of the number plate. 



5-44 



STEERING 



CHAS 



<$%) 



EC560000 

STEERING 




TIGHTENING STEPS: 



►Tighten ring nut. 

38 Nm (3.8 mkg, 27 ftlb) 
» Loosen it one turn. 
» Retighten it. 

7 Nm (0.7 mkg, 5.1 fMb) 



Extent of removal: 






© Under bracket removal 




© Bearing removal 


Extent of removal 


Order 


Part name 


Q'ty 


Remarks 


Preparation for removal 




STEERING REMOVAL 

Hold the machine by placing the 




rmvAUJiLVd 


Support the machine securely so there is no 






suitable stand under the engine. 

Number plate 

Handlebar 




danger of it falling over. 


Refer to "HANDLEBAR" section. 






Cable guide 










Front fender 








' 




1 


Steering shaft nut 


1 










2 


Front fork 


2 


Refer to "FRONT FORK" section. 


A 


) 




3 


Handle crown 






vj 




4 


Ring nut 




Use special tool. 




(?) 








Refer to "REMOVAL POINTS". 








5 


Under bracket 










6 


Ball race cover 










7 


Bearing (upper) 










8 


Bearing (lower) 




Refer to "REMOVAL POINTS". 






9 


Ball race 


2 


Refer to "REMOVAL POINTS". 



5-45 



STEERING 



CHAS 



<$%) 




EC563000 

REMOVAL POINTS 

EC563202 

Ring nut 

1 . Remove: 
• Ring nut © 
Use the ring nut wrench ©. 



/- 



Ring nut wrench: 
YU-33975/90890-01403 



A WARNING 



Support the steering shaft so that it may 
not fall down. 




EC563300 

Bearing (lower) 

1 . Remove: 

• Bearing (lower) © 
Use the floor chisel ©. 

CAUTION: 



Take care not to damage the steering shaft 
thread. 



EC563400 

Ball race 

1 . Remove: 
• Ball race © 
Remove the ball race using long rod 
and the hammer. 



EC564000 

INSPECTION 

EC564200 

Steering shaft 

1. Inspect: 

• Steering shaft © 
Bend/damage -^ Replace. 



5-46 



STEERING 



CHAS 



(fab 




EC564101 

Bearing and ball race 

1 . Wash the bearings and ball races with a 
solvent. 

2. Inspect: 

• Bearing © 

• Ball race 

Pitting/damage -> Replace bearings 
and ball races as a set. 
Install the bearing in the ball races. 
Spin the bearings by hand. If the bear- 
ings hang up or are not smooth in their 
operation in the ball races, replace 
bearings and ball races as a set. 




EC565000 

ASSEMBLY AND INSTALLATION 
Under bracket 

1. Install: 

• Bearing (lower) © 

NOTE: 

Apply the lithium soap base grease on the dust 
seal lip and bearing inner circumference. 



2. Install: 

• Ball race 

• Bearing (upper) © 

• Ball race cover ® 

NOTE: 

Apply the lithium soap base grease on the 
bearing and ball race cover lip. 



Install: 

• Under bracket © 



NOTE: 

Apply the lithium soap base grease on the 
bearing, the portion ® and thread of the steer- 
ing shaft. 



5-47 



STEERING 



CHAS 



(fab 




Install: 

• Ring nut © 



7 Nm (0.7 m • kg, 5.1 ft • lb) 



Tighten the ring nut using the ring nut 
wrench ©. 

Refer to "STEERING HEAD INSPEC- 
TION AND ADJUSTMENT" section in 
the CHAPTER 3. 



5. Check the steering shaft by turning it lock 
to lock. If there is any binding, remove the 
steering shaft assembly and inspect the 
steering bearings. 



6. Install: 

• Front fork © 

• Handle crown © 

NOTE: 

• Temporarily tighten the pinch bolts (under 
bracket). 

• Do not tighten the pinch bolts (handle crown) 
yet. 

7. Install: 

• Plain washer © 



Steering shaft nut © 



145 Nm (14.5 m ■ kg, 105 ft • lb) 



8. After tightening the nut, check the steer- 
ing for smooth movement. If not, adjust 
the steering by loosening the ring nut little 
by little. 

9. Adjust: 

• Front fork top end ® 




Front fork top end (standard) ® 
Zero mm (Zero in) 



5-48 



STEERING 



CHAS 



<$%) 




10. Tighten: 

• Pinch bolt (handle crown) © 



23 Nm (2.3 m kg, 17 ft lb) 



Pinch bolt (under bracket) (2) 



20 Nm (2.0 m kg, 14 ft lb) 



Tighten the under bracket to specified 
torque. If torqued too much, it may cause 
the front fork to malfunction. 



5-49 



SWINGARM 



CHAS 



<$%) 



EC570000 

SWINGARM 




85 Nm (8.5 m - kg, 61 ft - lb) 



80 Nm (8.0 m - kg, 58 ft - lb) 



Extent of removal: 



© Swingarm removal 



Extent of removal 


Order 


Part name 


Q'ty 


Remarks 


Preparation for removal 




SWINGARM REMOVAL 

Hold the machine by placing the 
suitable stand under the engine. 

Brake hose holder 






| A WARNING | 


Support the machine securely so there is no 
danger of it falling over. 


-, Refer to "FRONT BRAKE AND REAR 
-T BRAKE" section. 






Rear caliper 








Bolt (brake pedal) 
Drive chain 




Shift the brake pedal backward. 






1 
2 


Chain support 

Chain tensioner (lower) 






c 


) 


3 

4 
5 


Bolt (rear shock absorber-relay 

arm) 

Bolt (connecting rod) 

Pivot shaft 




Hold the swingarm. 






6 


Swingarm 







5-50 



SWINGARM 



CHAS 



(fab 



EC578000 

SWINGARM DISASSEMBLY 



2 Nm (0.2 m -kg, 1.4 ft -lb) 



6 Nm (0.6 m • kg, 4.3 ft • lb) 




80 Nm (8.0 m - kg, 58 ft - lb) 



-^M»* 



Extent of removal: 



© Swingarm disassembly © Connecting rod removal and disassembly 

© Relay arm removal and disassembly 



Extent of removal 


Order 


Part name 


Q'ty 


Remarks 






SWINGARM DISASSEMBLY 






■ 


I ® 


© 


Cap 


2 






© 


Relay arm 


1 






©| 


© 


Connecting rod 


1 








© 


Collar 


2 




© 


© 


Oil seal 


2 








© 


Thrust bearing 


2 








© 


Bush 


2 






i) (I) 

i 1 1 


© 


Oil seal 


8 






© 


Bearing 


8 


Refer to "REMOVAL POINTS". 



5-51 



SWINGARM 



CHAS 



(fab 




EC573000 

REMOVAL POINTS 

EC573200 

Bearing 

1 . Remove: 
• Bearing © 

NOTE: 

Install the bearing by pressing its outer race. 



EC574010 

INSPECTION 

Wash the bearings, bushes, collars, and cov- 
ers in a solvent. 

EC5741 1 1 

Swingarm 

1. Inspect: 

• Bearing © 

• Bush © 

Free play exists/unsmooth revolution/ 
rust -^ Replace bearing and bush as a 
set. 

2. Inspect: 

• Oil seal © 
Damage -^ Replace. 




EC574210 

Relay arm 

1. Inspect: 

• Bearing (polylube bearing) © 

• Collar © 

Free play exists/unsmooth revolution/rust 
-^ Replace bearing and collar as a set. 

2. Inspect: 

• Bearing (polylube bearing) © 
Loss of solid lubrication -^ Replace. 

• Oil seal © 
Damage -^ Replace. 

NOTE: 

Polylube bearings, with solid lubrication, have 
been adopted with the intent to make the nee- 
dle bearings, used in this model, maintenance 
free. With polylube bearings, no grease nipple 
and regular lubrication is necessary. However, 
grease should be applied to all oil seals and 
collars when removed or installed. 



5-52 



SWINGARM 



CHAS 



(fab 




EC574310 

Connecting rod 

1. Inspect: 

• Bearing (polylube bearing) © 

• Collar © 

Free play exists/unsmooth revolution/rust 
-^ Replace bearing and collar as a set. 

2. Inspect: 

• Bearing (polylube bearing) © 
Loss of solid lubrication -^ Replace. 

• Oil seal © 
Damage -^ Replace. 

NOTE: 

Polylube bearings, with solid lubrication, have 
been adopted with the intent to make the nee- 
dle bearings, used in this model, maintenance 
free. With polylube bearings, no grease nipple 
and regular lubrication is necessary. However, 
grease should be applied to all oil seals and 
collars when removed or installed. 





H=H* 



® 



►-< — — >- 




© 



© 



< >■ 



® 



EC575000 

ASSEMBLY AND INSTALLATION 

EC575201 

Bearing and oil seal 

1. Install: 

• Bearing © 

• Oil seal © 
To swingarm. 

NOTE: 

• Apply the molybdenum disulfide grease on 
the bearing when installing. 

• Install the bearing by pressing it on the side 
having the manufacture's marks or numbers. 

• First install the outer and then the inner bear- 
ings to a specified depth from inside. 




Installed depth of bearings: 
Outer (a): Zero mm (Zero in) 
Inner ©: 8.5 mm (0.33 in) 



5-53 



SWINGARM 



CHAS 



(fab 




2. Install: 

• Bearing © 

• Oil seal © 
To relay arm. 

NOTE: 

• Apply the molybdenum disulfide grease on 
the bearing when installing. 

• Install the bearing by pressing it on the side 
having the manufacture's marks or numbers. 




Installed depth of bearings ®: 
5 mm (0.20 in) 



& i 7C i l N u te 



®, 



a£ 



3-i r^ nx 



,® 






(2) 




-f^$P\ 


#^M*^ 










■MB— £- 




— \D 



3. Install: 

• Bearing © 

• Oil seal © 

To connecting rod. 

NOTE: 

• Apply the molybdenum disulfide grease on 
the bearing when installing. 

• Install the bearing by pressing it on the side 
having the manufacture's marks or numbers. 




Installed depth of bearings ® 
5 mm (0.20 in) 



Swingarm 

1. Install: 

• Bush © 

• Thrust bearing 

• Oil seal © 

• Collar © 

To swingarm (5 

NOTE: 



Apply the molybdenum disulfide grease on the 
bushes, thrust bearings and oil seal lips. 

2. Install: 
• Collar © 
To relay arm ©. 

NOTE: 

Apply the molybdenum disulfide grease on the 
collars and oil seal lips. 



5-54 



SWINGARM 



CHAS 



(fab 








3. Install: 
• Collar © 
To connecting rod 

NOTE: 



Apply the molybdenum disulfide grease on the 
collar and oil seal lips. 



4. Install: 

• Connecting rod © 

• Bolt (connecting rod) © 

• Plain washer © 

• Nut (connecting rod) © 



80 Nm (8.0 m • kg, 58 ft • lb) 



To relay arm ©. 

NOTE: 

Apply the molybdenum disulfide grease on the 
bolt. 



5. Install: 

• Relay arm © 

• Bolt (relay arm) © 

• Plain washer © 

• Nut (relay arm) © 
To swingarm. 

NOTE: 

• Apply the molybdenum disulfide grease on 
the bolt. 

• Do not tighten the nut yet. 

6. Install: 

• Swingarm © 



Pivot shaft © 



85 Nm (8.5 m • kg, 61 ft • lb) 



NOTE: 

• Apply the molybdenum disulfide grease on 
the pivot shaft. 

• Insert the pivot shaft from right side. 

7. Check: 

• Swingarm side play ® 

Free play exists -^ Replace thrust bear- 
ing. 

• Swingarm up and down movement © 
Unsmooth movement/binding/rough 
spots -> Grease or replace bearings, 
bushes and collars. 



5-55 



SWINGARM 



CHAS 



(fab 




8. Install: 

• Bolt (connecting rod) © 

• Plain washer © 

• Nut (connecting rod) ® 

NOTE: 

• Apply the molybdenum disulfide grease on 
the bolt. 

• Do not tighten the nut yet. 



9. Install: 

• Bolt (rear shock absorber-relay arm) © 

• Nut (rear shock absorber-relay arm) © 



53 Nm (5.3 m • kg, 38 ft • lb) 



NOTE: 

Apply the molybdenum disulfide grease on the 
bolt. 



10. Tighten: 

• Nut (connecting rod) © 



80 Nm (8.0 m • kg, 58 ft • lb) 



11. Tighten: 

• Nut (relay arm) © 



80 Nm (8.0 m • kg, 58 ft • lb) 



12. Install: 
• Cap© 

NOTE: 



Install the cap (right) with its mark ® facing 
forward. 



5-56 



SWINGARM 



CHAS 



(fab 




13. Install: 

• Bolt [chain tensioner (lower)] © 

• Plain washer © 

• Collar © 

• Chain tensioner 

• Nut [chain tensioner (lower)] © 



20 Nm (2.0 m kg, 14 ft lb) 



14. Install: 

• Chain support © 

• Support cover © 

• Bolt {chain support [ I - 50 mm (1 .97 in)]} 



® 

Nut (chain support) © 





X 


7 Nm (0.7 m 


•kg, 


5.1 ft 


lb) 


• Bolt {support 


covert = 10 mm (0.39 in)]} 


© 


X 


7 Nm (0.7 m 


•kg, 


5.1 ft 


lb) I 



5-57 



REAR SHOCK ABSORBER 



CHAS 



<$%) 



EC580000 

REAR SHOCK ABSORBER 



56 Nm (5.6 m - kg, 40 ft » lb) 




32 Nm (3.2 m • kg, 23 ft • lb) 



Extent of removal: 






© Rear shock absorber removal 




© Rear shock absorber disassembly 


Extent of removal 


Order 


Part name 


Q'ty 


Remarks 


Preparation for removal 




REAR SHOCK ABSORBER 
REMOVAL 

Hold the machine by placing the 
suitable stand under the engine. 
Seat and fitting band 

Silencer 




| A WARNING | 


Support the machine securely so there is no 
danger of it falling over. 


Refer to "SEAT, FUEL TANK AND SIDE 
COVERS" section in the CHAPTER 4. 
Refer to "EXHAUST PIPE AND 
SILENCER" section in the CHAPTER 4. 


c 


) 


D 


1 
2 
3 

4 
5 
6 
7 
8 


Clamp (air filter joint) 

Rear frame 

Bolt (rear shock absorber-relay 

arm) 

Bolt (rear shock absorber-frame) 

Rear shock absorber 

Locknut 

Adjuster 

Spring guide (lower) 




Only loosening. 
Hold the swingarm. 

Only loosening. 
Only loosening. 



5-58 



REAR SHOCK ABSORBER 



CHAS 



(fab 



56 Nm (5.6 m - kg, 40 ft • lb) 




32 Nm (3.2 m • kg, 23 ft • lb) 



Extent of removal 


Order 


Part name 


Q'ty 


Remarks 


I 


9 
10 
11 


Spring guide (upper) 
Spring (rear shock absorber) 
Bearing 


1 
1 
2 


Refer to "REMOVAL POINTS". 



5-59 



REAR SHOCK ABSORBER 



CHAS 



<$%) 



EC586000 

HANDLING NOTE 



A WARNING 



This shock absorber is provided with a 
separate type tank filled with high-pressure 
nitrogen gas. To prevent the danger of 
explosion, read and understand the follow- 
ing information before handling the shock 
absorber. 

The manufacturer can not be held respon- 
sible for property damage or personal 
injury that may result from improper han- 
dling. 

1. Never tamper or attempt to disassem- 
ble the cylinder or the tank. 

2. Never throw the shock absorber into 
an open flame or other high heat. The 
shock absorber may explode as a 
result of nitrogen gas expansion and/ 
or damage to the hose. 

3. Be careful not to damage any part of 
the gas tank. A damaged gas tank will 
impair the damping performance or 
cause a malfunction. 

4. Take care not to scratch the contact 
surface of the piston rod with the cylin- 
der; or oil could leak out. 

5. Never attempt to remove the plug at 
the bottom of the nitrogen gas tank. It 
is very dangerous to remove the plug. 

6. When scrapping the shock absorber, 
follow the instructions on disposal. 




EC587000 

NOTES ON DISPOSAL (YAMAHA DEALERS 
ONLY) 

Before disposing the shock absorber, be sure 
to extract the nitrogen gas from valve ©. Wear 
eye protection to prevent eye damage from 
escaping gas and/or metal chips. 



A WARNING 



To dispose of a damaged or worn-out 
shock absorber, take the unit to your 
Yamaha dealer for this disposal procedure. 



5-60 



REAR SHOCK ABSORBER 



CHAS 



gN> 





U4 




/////////// 






*u 












( 




\ 


JL 
T 1 M. 


INT 






u) 


\\ 


\\\\\V\\\ 



12340401 




EC583000 

REMOVAL POINTS 

EC583320 

Bearing 

1 . Remove: 

• Stopper ring (upper bearing) © 

NOTE: 

Press in the bearing while pressing its outer 
race and remove the stopper ring. 

2. Remove: 

• Upper bearing © 

NOTE: 

Remove the bearing by pressing its outer race. 



3. Remove: 

• Lower bearing © 

NOTE: 



Remove the bearing by pressing its outer race. 



EC584000 

INSPECTION 

Rear shock absorber 

1. Inspect: 

• Damper rod © 

Bends/damage -^ Replace absorber 
assembly. 

• Shock absorber © 

Oil leaks -^ Replace absorber assem- 
bly. 

Gas leaks -^ Replace absorber assem- 
bly. 

• Spring © 

Damage -^ Replace spring. 
Fatigue -^ Replace spring. 
Move spring up and down. 

• Spring guide © 

Wear/damage -^ Replace spring guide. 

• Bearing © 

Free play exists/unsmooth revolution/ 
rust -^ Replace. 



5-61 



REAR SHOCK ABSORBER 



CHAS 



<$%) 




EC585000 

ASSEMBLY AND INSTALLATION 

EC585300 

Bearing 

1. Install: 

• Upper bearing © 

NOTE: 

Install the bearing parallel until the stopper ring 
groove appears by pressing its outer race. 

CAUTI 



Do not apply the grease on the bearing 
outer race because it will wear the rear 
shock absorber surface on which the bear- 
ing is press fitted. 







w* 




I 

) 






\1 — (DISEffl 


3§P 




i 








//////// 


// 



2. Install: 

• Stopper ring (upper bearing) © 

NOTE: 



After installing the stopper ring, push back the 
bearing until it contacts the stopper ring. 







*U 














A 




v 




1 


\ 


IV 


b 




U) 




\\\\\\w\\\ 



3. Install: 

• Lower bearing © 

NOTE: 



Install the bearing by pressing it on the side 
having the manufacture's marks or numbers. 




Installed depth of the bearing ®: 
4 mm (0.16 in) 




EC5851 1 1 

Spring (rear shock absorber) 

1. Install: 

• Spring © 

• Spring guide (upper) © 

• Spring guide (lower) © 



5-62 



REAR SHOCK ABSORBER 



CHAS 



<$%) 




2. Tighten: 
• Adjuster © 



3. Adjust: 

• Spring length (installed) ® 



£ 


Spring length (installed) ®: 


Standard 
length 


Extent of 
adjustment 


249 mm (9.80 in) 
*264mm(10.39in) 


240,5 - 258.5 mm 

(9.47 -10.18 in) 

*255.5 ~ 273.5 mm 

(10.06 -10.77 in) 



* For EUROPE 
NOTE: 



The length of the spring (installed) changes 
1 .5 mm (0.06 in) per turn of the adjuster. 




. . ; II 

Never attempt to turn the adjuster beyond 
the maximum or minimum setting. 

4. Tighten: 
• Locknut © 



Rear shock absorber 

1. Install: 

• Dust seal © 

• O-ring © 

• Collar © 

NOTE: 



• Apply the molybdenum disulfide grease on 
the bearing. 

• Apply the lithium soap base grease on the 
dust seals, O-rings and collars. 



5-63 



REAR SHOCK ABSORBER 



CHAS 



gN> 









2. Install: 

• Bush © 

• Collar © 

• Dust seal © 

NOTE: 

• Apply the molybdenum disulfide grease on 
the bearing. 

• Apply the lithium soap base grease on the 
bush, collars and dust seals. 

• Install the dust seals with their lips facing 
outward. 

3. Install: 

• Rear shock absorber 

4. Install: 

• Bolt (rear shock absorber-frame) © 

• Nut (rear shock absorber-frame) © 



56 Nm (5.6 m • kg, 40 ft • lb) 



NOTE: 

Apply the molybdenum disulfide grease on the 
bolt. 

5. Install: 

• Bolt (rear shock absorber-relay arm) © 

• Nut (rear shock absorber-relay arm) © 



53 Nm (5.3 m • kg, 38 ft • lb) 



NOTE: 

Apply the molybdenum disulfide grease on the 
bolt. 





6. Install: 

• Rear frame © 



Bolt [rear frame (upper)] © 



32 Nm (3.2 m • kg, 23 ft • lb) 



Bolt [rear frame (lower)] © 



29 Nm (2.9 m • kg, 21 ft • lb) 




7. Tighten: 

• Screw (air filter joint) © 



3 Nm (0.3 m • kg, 2.2 ft • lb) 



5-64 



ELECTRICAL COMPONENTS AND WIRING DIAGRAM 



ELEC 



EC600000 

ELECTRICAL 

EC610000 

ELECTRICAL COMPONENTS AND WIRING DIAGRAM 

EC611000 

ELECTRICAL COMPONENTS 



©"ENGINE STOP" button 

© TPS (throttle position sensor) 

© Neutral switch 

© CDI magneto 

© Ignition coil 

© Spark plug 

©CDI unit 



COLOR CODE 

B Black 

Br Brown 

G Green 

L Blue 

O Orange 

P Pink 

R Red 

Sb Sky blue 



W White 

Y Yellow 

B/L Black/Blue 

B/W Black/White 

B/Y Black/Yellow 

G/B Green/Black 

L/W Blue/White 

R/W Red/White 





EC612000 

WIRING DIAGRAM 




6-1 



MAP-CONTROLLED CDI UNIT 



ELEC 



MAP-CONTROLLED CDI UNIT 

A map-controlled, CDI ignition system is used in the YZ450F. 

The microcomputer in the CDI unit detects the engine speed and throttle position, thus determining 
the optimum ignition timing through the entire operating range. In this way, quick throttle response 
can be achieved according to various riding conditions. 



Throttle position sensor 



7>- 



o- 



CDI unit 



-0 



< — o 
— 6 



o- 



6- 



-o- 



Ignition coil 




Pickup coil CDI magneto rotor 



7tr 



I Function of Component 



Component 


Function 


TPS 

(throttle position sensor) 


Detects throttle valve opening and inputs it into the computer in the 
CDI unit as a throttle opening signal. 


Pickup coil 


Detects signal rotor revolutions and inputs them into the computer in 
the CDI unit as engine revolution signals. 


CDI unit 


The signals of the TPS and pickup coil sensor are analyzed by the 
computer in the CDI unit, which then adjusts ignition timing for the 
operation requirements. 



■ Principal of 3-Dimensional Control 

Conventionally, ignition timing was controlled only 
by engine revolutions (2-dimensional control). 
However, ignition timing needs advancement also 
by engine load. Thus, accurate ignition timing can 
be determined by adding throttle opening to deter- 
mine ignition timing (3-dimensional control). 




3-D Image Map of Ignition Timing 
(different from actual characteristics) 



6-2 



IGNITION SYSTEM 



ELEC 



EC620000 

IGNITION SYSTEM 

INSPECTION STEPS 

Use the following steps for checking the possibility of the malfunctioning engine being attributable to 
ignition system failure and for checking the spark plug which will not spark. 



Spark gap test 



Spark 



*Clean or replace 
spark plug. 



No spark 



Check entire ignition 

system for connection. 

(couplers, leads and 

ignition coil) 

^L> OK 



No good 



Repair or replace. 



Check "ENGINE STOP" 
button. 

^> OK 



No good 



Replace. 



Check ignition coil. 



OK 



Primary coil 



No good 



Replace. 



Secondary coil 



No good 



Replace. 



<Z- 



Check CDI magneto. 



OK 



Pick-up coil 



No good 



Replace. 



Source coil 



No good 



Replace. 



<Z- 



Check neutral switch. 
^> OK 



No good 



Repair or replace. 



Replace CDI unit. 



*marked: Only when the ignition checker is used. 
NOTE: 



• Remove the following parts before inspection. 

1) Seat 

2) Fuel tank 

• Use the following special tools in this inspection. 




Dynamic spark tester: 

YM-34487 
Ignition checker: 

90890-06754 



^ 



Pocket tester: 
YU-3112-C/90890-03112 



6-3 



IGNITION SYSTEM 



ELEC 



W 









- c 


5 10 




35=01' 



a 




SPARK GAP TEST 

1. Disconnect the ignition coil from spark 
plug. 

2. Remove the ignition coil cap. 

3. Connect the dynamic spark tester © 
(ignition checker ©) as shown. 

• Ignition coil © 

• Spark plug © 

S For USA and CDN 

M Except for USA and CDN 

4. Kick the kick starter. 

5. Check the ignition spark gap. 

6. Start engine, and increase spark gap until 
misfire occurs, (for USA and CDN only) 




Minimum spark gap: 
6.0 mm (0.24 in) 



COUPLERS, LEADS AND IGNITION COIL 
CONNECTION INSPECTION 

1. Check: 

• Couplers and leads connection 
Rust/dust/looseness/short-circuit -> 
Repair or replace. 

• Ignition coil and spark plug as they are 
fitted 

Push in the ignition coil until it closely 
contacts the spark plug hole in the cyl- 
inder head cover. 




EC625001 

"ENGINE STOP" BUTTON INSPECTION 

1. Inspect: 

• "ENGINE STOP" button conduct 



Tester (+) lead -» Black/White lead © 
Tester (-) lead -> Black lead © 




d„ 




B/W 

© 


B 
© 


Tester selec- 
tor position 




PUSH IN 


O 


O 


Qx1 


FREE 







No continuity while being pushed -> Replace. 
Continuity while being freed -> Replace. 



6-4 



IGNITION SYSTEM 



ELEC 





EC626002 

IGNITION COIL INSPECTION 

1 . Remove the ignition coil cap. 

2. Inspect: 

• Primary coil resistance 
Out of specification -> Replace. 



Tester (+) lead -^ Orange lead © 
Tester (-) lead -> Black lead © 



eii 


Primary coil 
resistance 


Tester selector 
position 




0.08 - 0.1 0Q at 
20 °C (68 °F) 


Qx1 





Y 


A 




w 


Br 


P 


R 


G 


B 



3. Inspect: 

• Secondary coil resistance 
Out of specification -> Replace. 



Tester (+) lead -> Spark plug terminal © 
Tester (-) lead -> Orange lead © 



HU 


Secondary coil 
resistance 


Tester selector 
position 




4.6 ~ 6.8 kQ at 
20 °C (68 °F) 


kQxl 



4. Inspect: 

• Sealed portion of ignition coil ® 

• Spark plug terminal pin (b) 

• Threaded portion of spark plug © 
Wear -^ Replace. 

EC62701 1 

CDI MAGNETO INSPECTION 

1. Inspect: 

• Pick-up coil resistance 

Out of specification -> Replace. 



Tester (+) lead -^ Red lead © 
Tester (-) lead -> White lead Q 



Oi 


Pick-up coil 
resistance 


Tester selector 
position 




248 ~ 372 Q at 
20 °C (68 °F) 


Qx100 



6-5 



IGNITION SYSTEM 



ELEC 




2. Inspect: 

• Source coil 1 resistance 
Out of specification -> Replace. 



Tester (+) lead -> Brown lead © 
Tester (-) lead -> Green lead © 



HU 


Source coil 1 
resistance 


Tester selector 
position 




720 ~ 1,080 Q 
at 20 °C (68 °F) 


Qx100 



3. Inspect: 

• Source coil 2 resistance 
Out of specification -^ Replace. 



Tester (+) lead -^ Pink lead © 
Tester (-) lead -> Black lead (g 



Oi 


Source coil 2 
resistance 


Tester selector 
position 




44 ~ 66 Q at 
20 °C (68 °F) 


Qx10 



















rr\ 


Qx1 


© 






/\ 




I 














iDU 











NEUTRAL SWITCH INSPECTION 

1. Inspect: 

• Neutral switch conduct 



Tester (+) lead -^ Sky blue lead © 
Tester (-) lead -^ Ground 




ii 




Sb 

© 


Ground 


Tester selec- 
tor position 




NEUTRAL 


r\ 


D 


Qx1 


vJ 


vJ 


IN GEAR 







No continuity while in neutral -> Replace. 
Continuity while in gear -> Replace. 

EC628000 

CDI UNIT INSPECTION 

Check all electrical components. If no fault is 
found, replace the CDI unit. Then check the 
electrical components again. 



6-6 



TPS (THROTTLE POSITION SENSOR) SYSTEM 



ELEC 



TPS (THROTTLE POSITION SENSOR) SYSTEM 

INSPECTION STEPS 

If the TPS will not operate, use the following inspection steps. 



Check entire ignition 
system for connection. 



No good 



<y ok 




Check TPS. 





^Z 



TPS coil 



No good 



OK 



*Check CDI magneto. 
<> OK 



Source coil 



No good 



Check CDI unit. 



TPS input 
voltage 



No good 



*marked: Refer to "IGNITION SYSTEM" section. 
NOTE: 



Repair or replace. 



Replace. 



Replace. 



Replace. 



Use the following special tools in this inspection. 



y> 



Pocket tester: 
YU-3112-C/90890-03112 



^ 



Inductive tachometer: 

YU-8036-B 
Engine tachometer: 

90890-03113 



6-7 



TPS (THROTTLE POSITION SENSOR) SYSTEM 



ELEC 




HANDLING NOTE 



MMMMB 



Do not loosen the screws {TPS (throttle 
position sensor)} © except when changing 
the TPS (throttle position sensor) due to 
failure because it will cause a drop in 
engine performance. 



EC624000 

COUPLERS AND LEADS CONNECTION 
INSPECTION 

1. Check: 

• Couplers and leads connection 
Rust/dust/looseness/short-circuit -» 
Repair or replace. 




TPS COIL INSPECTION 

1. Inspect: 

• TPS coil resistance 
Out of specification -^ Replace. 



Tester (+) lead -^ Blue lead © 
Tester (-) lead -> Black lead (g 



SN 


TPS coil 
resistance 


Tester selector 
position 




4 ~ 6 kQ at 
20 °C (68 T) 


kQxl 



2. Loosen: 

• Throttle stop screw © 



NOTE: 

Turn out the throttle stop screw until the throt- 
tle shaft is in the full close position. 



6-8 



TPS (THROTTLE POSITION SENSOR) SYSTEM 



ELEC 




Inspect: 

• TPS coil variable resistance 
Check that the resistance in increased 
as the throttle grip is moved from the 
full close position to the full open posi- 
tion. 
Out of specification -^ Replace. 



Tester (+) lead -> Yellow lead © 
Tester (-) lead -> Black lead © 



SI 


TPS coil variable 
resistance 


Tester selec- 
tor position 




Full closed 


Full opened 


kQxl 


- 2 kQ at 
20 °C 
(68 T) 


4 ~ 6 kQ, at 

20 °C 

(68 T) 




TPS REPLACEMENT AND ADJUSTMENT 

1 . Remove: 

• TPS coupler 

• Screw (TPS) © 

• TPS© 

NOTE: 

Loosen the screws (TPS) using the T25 bit. 

2. Replace: 

• TPS 

3. Install: 

• TPS© 

• Screw (TPS) © 

• TPS coupler 

NOTE: 

• Align the slot ® in the TPS with the projec- 
tion (£) on the carburetor. 

• Temporarily tighten the screws (TPS). 



6-9 



TPS (THROTTLE POSITION SENSOR) SYSTEM 



ELEC 




Adjust: 

• Idle speed 



Adjustment steps: 

• Attach the inductive tachometer (engine 
tachometer) to the high tension cord. 

• Turn the throttle stop screw © until the 
specified idle speed. 

Refer to "IDLE SPEED ADJUSTMENT" 
section in the CHAPTER 3. 




Idle speed: 
1,900 ~ 2,100 r/min 



5. Insert the thin electric conductors (2) 
(lead) into the TPS coupler ©, as shown, 
and connect the tester to them. 



Tester (+) lead -^ Yellow lead (§ 
Tester (-) lead -^ Black lead 



CAl J: _ 

• Do not insert 
more than 




the electric conductors 
required because it may 
reduce the waterproof function of the 
coupler. 
• Make sure that a short-circuit does not 
develop between the terminals because it 
may cause damage to electrical compo- 
nents. 

6. Start the engine. 

7. Adjust: 

• TPS output voltage 



Adjustment steps: 

Adjust the installation angle of the TPS © 
to obtain the specified output voltage. 

NOTE: 



Measure the output voltage accurately with a 
digital electronic voltmeter that gives an easy 
reading of a small voltage. 



Oi 


TPS output 
voltage 


Tester selector 
position 




0.58 ~ 0.78 V 


DCV 



6-10 



TPS (THROTTLE POSITION SENSOR) SYSTEM 



ELEC 




8. Tighten: 

• Screw (TPS) © 

9. Stop the engine. 



EC694000 

TPS INPUT VOLTAGE INSPECTION 

1 . Disconnect the TPS coupler. 

2. Start the engine. 

3. Inspect: 

• TPS input voltage 
Out of specification -^ Replace the CDI 
unit. 



Tester (+) lead -> Blue lead © 
Tester (-) lead -^ Black/Blue lead 



Oi 


TPS input 
voltage 


Tester selector 
position 




4~6V 


DCV-20 



6-11 



SETTING 




EC700000 

TUNING 

EC710000 

ENGINE 

Carburetor setting 

• The air/fuel mixture will vary depending on 
atmospheric conditions. Therefore, it is nec- 
essary to take into consideration the air pres- 
sure, ambient temperature, humidity, etc., 
when adjusting the carburetor. 

• Perform a test run to check for proper engine 
performance (e.g., throttle response) and 
spark plug(-s) discoloration or fouling. Use 
these readings to determine the best possi- 
ble carburetor setting. 

NOTE: 

It is recommended to keep a record of all car- 
buretor settings and external conditions (e.g., 
atmospheric conditions, track/surface condi- 
tions, lap times) to make future carburetor set- 
ting easier. 



A WARNING 



• The carburetor is a part of the fuel line. 
Therefore, be sure to install it in a well- 
ventilated area, away from flammable 
objects and any sources of fire. 

• Never look into the carburetor intake. 
Flames may shoot out from the pipe if the 
engine backfires while it is being started. 
Gasoline may be discharged from the 
accelerator pump nozzle when the carbu- 
retor has been removed. 




7-1 



SETTING 




1^ 

• The carburetor is extremely sensitive to 
foreign matter (dirt, sand, water, etc.). 
During installation, do not allow foreign 
matter to get into the carburetor. 

• Always handle the carburetor and its 
components carefully. Even slight 
scratches, bends or damage to carbure- 
tor parts may prevent the carburetor from 
functioning correctly. Carefully perform 
all servicing with the appropriate tools 
and without applying excessive force. 

• When the engine is stopped or when 
riding at no load, do not open and close 
the throttle unnecessarily. Otherwise, too 
much fuel may be discharged, starting 
may become difficult or the engine may 
not run well. 

• After installing the carburetor, check that 
the throttle operates correctly and opens 
and closes smoothly. 

Atmospheric conditions and carburetor 
settings 



Air temp. 


Humidity 


Air 
pressure 
(altitude) 


Mixture 


Setting 


High 


High 


Low (high) 


Richer 


Leaner 


Low 


Low 


High (low) 


Leaner 


Richer 



The air density (i.e., concentration of oxygen 
in the air) determines the richness or lean- 
ness of the air/fuel mixture. Therefore, refer 
to the above table for mixture settings. 
That is: 

• Higher temperature expands the air with its 
resultant reduced density. 

• Higher humidity reduces the amount of oxy- 
gen in the air by so much of the water vapor 
in the same air. 

• Lower atmospheric pressure (at a high alti- 
tude) reduces the density of the air. 



7-2 



SETTING 





S Closed 
\b\ Fully open 



Effects of the setting parts on the throttle 
valve opening 




© Pilot screw/pilot jet 
© Throttle valve cutaway 
© Jet needle 
© Main jet 




Main system 

The FLATCR carburetor has a primary main 

jet. This type of main jet is perfect for racing 

motorcycles since it supplies an even flow of 

fuel, even at full load. Use the main jet and the 

jet needle to set the carburetor. 

© Jet needle 

© Pilot air jet 

© Needle jet 

© Main jet 

©Pilot jet 

© Pilot screw 



7-3 



SETTING 




Pilot system 

The FLATCR carburetor is manufactured with 
a pilot screw. The pilot screw adjustment 
ranges from fully closed throttle to 1/4 open 
throttle. 




Main jet adjustment 

The richness of the air-fuel mixture at full throt- 
tle can be set by changing the main jet ©. 



Standard main jet 


#165 



If the air-fuel mixture is too rich or too lean, the 
engine power will drop, resulting in poor accel- 
eration. 

Effects of changing the main jet (reference) 



H 



1/4 



1/2 



3/4 











#168 
















#162 









+10% 

#165 

-10% 



Sidle 



Fully open 



7-4 



SETTING 





Pilot screw adjustment 

The richness of the air-fuel mixture with the 
throttle fully closed to 1/4 open can be set by 
turning the pilot screw ©. Turning in the pilot 
screw will make the mixture lean at low 
speeds, and turning it out will enrich it. 



Standard pilot 
screw position 


2 
(example) 



NOTE: 

• If the idling speed fluctuates, turn the pilot 
screw only 1/2 of a turn in either direction. 

• To optimize the fuel flow at a smaller throttle 
opening, each machine's pilot screw has 
been individually set at the factory. Before 
adjusting the pilot screw, turn it in fully and 
count the number of turns. Record this num- 
ber as the factory-set number of turns out. 

Effects of adjusting the pilot screw 
(reference) 



H 



1/4 



1/2 



3/4 







© 












© 













+5% 



-5% 



Sidle 

H] Fully open 
©2-1/2 turns out 
© 1-1/2 turns out 
® 2 turns out 



7-5 



SETTING 





Pilot jet adjustment 

The richness of the air-fuel mixture with the 
throttle open 1/4 or less can be set by adjust- 
ing the pilot jet ©. 



Standard pilot jet 


#42 



Effects of adjusting the pilot jet (reference) 

H 1/4 1/2 3/4 B 







#45 
















#40 













+5% 
#42 
-5% 



Sidle 



Fully open 




Jet needle groove position adjustment 

Adjusting the jet needle © position affects the 
acceleration when the throttle is 1/8 to 3/4 
open. 

1 . Too rich at intermediate speeds 

Rough engine operation is felt and the 
engine will not pick up speed smoothly. In 
this case, step up the jet needle clip by 
one groove and move down the needle to 
lean out the mixture. 

2. Too lean at intermediate speeds 

The engine breathes hard and will not 
pick up speed quickly. 
Step down the jet needle clip by one 
groove and move up the needle to enrich 
the mixture. 



Standard clip position 



No.4 groove 



Effects of changing the jet needle groove 
position (reference) 



H 


1 'i— 


1/2 


3/4 


m 




y 


© 


\ 


^^ 










s 


© 


S 


^ 












**•*■«. 


^ 











+10% 



-10% 



Sidle 

M Fully open 
© No. 5 groove 
© No. 3 groove 
© No.4 groove 



7-6 



SETTING 




Jet needle adjustment 

The jet needle is adjusted by changing it. 



Standard jet needle 


NCVQ 



The tapered sections of all jet needles have 
the same starting positions, but the needles 
are available with different straight-portion 
diameters. 



1 ; 

IN 


23456 

F ||| U 

m 


7 


F 


ll 1 




l> 









<Example> 
NCVQ - 4 



Clip position 

Diameter ® of straight portion 



Effects of changing the jet needle 
(reference) 

(Diameter of the straight portion) 
Changing the diameter of the straight portion 
adjusts the air-fuel mixture when the throttle is 
1/8 to 1/4 open. 



H 



1/4 



1/2 



3/4 









p 




















R 



















+10% 

Q 

-10% 



Sidle 



Fully open 



Relationship with throttle opening 

The flow of the fuel through the carburetor 
main system is controlled by the main jet and 
then, it is further regulated by the area 
between the main nozzle and the jet needle. 
The fuel flow relates to the diameter of the 
straight portion of the jet needle with the throt- 
tle 1/8 to 1/4 open and relates to the clip posi- 
tion with the throttle 1/8 to 3/4 open. 
Therefore, the fuel flow is balanced at each 
stage of throttle opening by the combination of 
the jet needle straight portion diameter, and 
clip position. 



7-7 



SETTING 




Carburetor setting parts 




Part name 


Size 


Part number 


Main jet Rich 


#178 


4MX-1 4943-93 


A 


#175 


4MX-1 4943-42 






#172 


4MX-1 4943-92 






#170 


4MX-1 4943-41 






#168 


4MX-1 4943-91 


(STD) 




#165 


4MX-1 4943-40 






#162 


4MX-1 4943-90 






#160 


4MX-1 4943-39 






#158 


4MX-1 4943-89 


]j 


#155 


4MX-1 4943-38 


Lean 


#152 


4MX-1 4943-88 


Pilot jet Rich 


#50 


4MX-1 4948-07 


A 


#48 


4MX-1 4948-06 






#45 


4MX-1 4948-05 


(STD) 




#42 


4MX-1 4948-04 






#40 


4MX-1 4948-03 


U 


#38 


4MX-1 4948-02 


Lean 


#35 


4MX-1 4948-01 


Jet needle Rich 


#CVM 


5TA-14916-VM 


A 


#CVN 


5TA-14916-VN 






#CVP 


5TA-14916-VP 


(STD) 




#CVQ 


5TA-14916-V1 






#CVR 


5TA-14916-VR 


M 


#CVS 


5TA-14916-VS 


Lean 


#CVT 


5TA-14916-VT 



7-8 



SETTING 




Examples of carburetor setting depending on symptom 



Symptom 


Setting 


Checking 


At full throttle 
Hard breathing 
Shearing noise 
Whitish spark plug 

Lean mixture 


Increase main jet calibration no. 
(Gradually) 


Discoloration of spark plug -> 

If tan color, it is in good condition. 
If cannot be corrected: 

Clogged float valve seat 

Clogged fuel hose 

Clogged fuel cock 
Check that the accelerator pump oper- 
ates smoothly. 


At full throttle 
Speed pick-up stops 
Slow speed pick-up 
Slow response 
Sooty spark plug 

Rich mixture 


Decrease main jet calibration no. 
(Gradually) 


Discoloration of spark plug -> 
If tan color, it is in good condition. 

If cannot be corrected: 
Clogged air cleaner 
Fuel overflow from carburetor 


Lean mixture 


Lower jet needle clip position. 
(1 groove down) 


Groobe 1 \ 
Groobe 2 C\^ 
Groobe 3~^§ 
Groobe ^—^M 
Groobe 5^/^P 
Groobe 6// 
Groobe 7 X l - 

Jet needle ^^ 


I Clip 

1^2) Leaner 

j t 

(Standard) 
Richer 


Rich mixture 


Raise jet needle clip position. 
(1 groove up) 


1/4-3/4 throttle 
Hard breathing 
Lack of speed 


Lower jet needle clip position. 
(1 groove down) 


1/4 -1/2 throttle 
Slow speed pick-up 
Poor acceleration 


Raise jet needle clip position. 
(1 groove up) 


The clip position is the jet needle 
groove on which the clip is installed. 
The positions are numbered from the 
top. 

Check that the accelerator pump oper- 
ates smoothly (except for rich mixture 
symptom). 


Closed to 1/4 throttle 
Hard breathing 
Speed down 


Use jet needle with a smaller diameter. 


Slow-speed-circuit passage 

Clogged -^ Clean. 
Overflow from carburetor 


Closed to 1/4 throttle 
Poor acceleration 


Use jet needle with a larger diameter. 
Raise jet needle clip position. (1 groove 
up) 




Poor response in the low to 
intermediate speeds 


Raise jet needle clip position. 

If this has no effect, lower the jet needle 

clip position. 




Poor response when throttle 
is opened quickly 


Check overall settings. 

Use main jet with a lower calibration no. 

Raise jet needle clip position. 

(1 groove up) 

If these have no effect, use a main jet 

with a higher calibration no. and lower 

the jet needle clip position. 


Check air cleaner for fouling. 

Check that the accelerator pump oper- 
ates smoothly. 



* This should be taken simply for an example. It is necessary to set the carburetor while checking 
the operating conditions of the engine. 



7-9 



SETTING 




EC720000 

CHASSIS 

EC71 P002 

Selection of the secondary reduction ratio 
(Sprocket) 



Secondary ki , t , . 

. x . Number of driven sprocket teeth 

reduction = 



Number of drive sprocket teeth 
ratio 



Standard secondary 
reduction ratio 



48/14(3.429) 
*47/14(3.357) 



• For EUROPE 

Requirement for selection of secondary gear 
reduction ratio 

• It is generally said that the secondary gear 
ratio should be reduced for a longer straight 
portion of a speed course and should be 
increased for a course with many corners. 
Actually, however, as the speed depends on 
the ground condition of the day of the race, 
be sure to run through the circuit to set the 
machine suitable for the entire course. 

• In actuality, it is very difficult to achieve set- 
tings suitable for the entire course and some 
settings may be sacrificed. Thus, the settings 
should be matched to the portion of the 
course that has the greatest effect on the 
race result. In such a case, run through the 
entire course while making notes of lap times 
to find the best balance; then, determine the 
secondary reduction ratio. 

• If a course has a long straight portion where 
a machine can run at maximum speed, the 
machine is generally set such that it can 
develop its maximum revolutions toward the 
end of the straight line, with care taken to 
avoid the engine over-revving. 

NOTE: 

Riding technique varies from rider to rider and 
the performance of a machine also vary from 
machine to machine. Therefore, do not imitate 
other rider's settings from the beginning but 
choose your own setting according to the level 
of your riding technique. 



7-10 



SETTING 





EC72N000 



Drive and driven sprockets setting parts 



Part name 


Size 


Part number 


Drive sprocket © 
(STD) 


14T 


9383E-14215 


Drive sprocket (2) 

*(STD) 

(STD) 


46T 
47T 
48T 
49T 
50T 
51T 
52T 


5TA-25446-00 
5ET-25447-00 
5NY-25448-00 
5NY-25449-00 
5NY-25450-00 
5NY-25451-00 
5NY-25452-00 



* For EUROPE 



EC721002 

Tire pressure 

Tire pressure should be adjust to suit the road 
surface condition of the circuit. 




Standard tire pressure: 
100 kPa (1.0 kgf/cm 2 , 15 psi) 



• Under a rainy, muddy, sandy, or slippery 
condition, the tire pressure should be lower 
for a larger area of contact with the road sur- 
face. 




Extent of adjustment: 
60 ~ 80 kPa 
(0.6 ~ 0.8 kgf/cm 2 , 9.0-12 psi) 



• Under a stony or hard road condition, the tire 
pressure should be higher to prevent a flat 
tire. 




Extent of adjustment: 
100~120kPa 
(1.0 ~ 1.2 kgf/cm 2 , 15-18 psi) 



7-11 



SETTING 




A| 

) 

E 

[kg (lb)] 


I 


-(D 
-<D 




\C\ [mm (in)] 



EC72201 1 

Front fork setting 

The front fork setting should be made depend- 
ing on the rider's feeling of an actual run and 
the circuit conditions. 

The front fork setting includes the following 
three factors: 

1 . Setting of air spring characteristics 

• Change the fork oil level. 

2. Setting of spring preload 

• Change the spring. 

• Install the adjustment washer. 

3. Setting of damping force 

• Change the compression damping. 

• Change the rebound damping. 

The spring acts on the load and the 
damping force acts on the cushion 
travel speed. 

EC723001 

Change in level and characteristics of fork 
oil 

Damping characteristic near the final stroke 
can be changed by changing the fork oil 
amount. 

CAUTION: 

Adjust the oil level in 5 mm (0.2 in) incre- 
ments or decrements. Too low oil level 
causes the front fork to produce a noise at 
full rebound or the rider to feel some pres- 
sure on his hands or body. Alternatively, 
too high oil level will develop unexpectedly 
early oil lock with the consequent shorter 
front fork travel and deteriorated perfor- 
mance an characteristics. Therefore, adjust 
the front fork within the specified range. 




Standard oil level: 
135 mm (5.31 in) 

Extent of adjustment: 
80 -150 mm (3.15-5.91 in) 
From top of outer tube with 
inner tube and damper rod fully 
compressed without spring. 



\M Air spring characteristics in relation to oil level 

change 
HLoad 
\c\ Stroke 
© Max. oil level 
© Standard oil level 
(3) Min. oil level 



7-12 



SETTING 





iu 



=2.3 mm 



a (0.09 in) 



l^ 



[kg (lb)] 




[mm (in)] 



EC727020 



Spring preload adjustment 

The spring preload is adjusted by installing the 
adjustment washer © between the fork spring 
© and damper rod ©. 



Do not install three or more adjustment 
washers for each front fork. 



A WARNING 



Always adjust each front fork to the same 
setting. Uneven adjustment can cause poor 
handling and loss of stability. 




Standard washer quantity: 
Zero adjustment washers 

Extent of adjustment: 
Zero - 2 adjustment washers 



[a] Load 

[H Fork stroke 

© Without adjustment washer (standard) 

© 1 adjustment washer 

© 2 adjustment washers 



EC72A001 

Setting of spring after replacement 

As the front fork setting can be easily affected 
by rear suspension, take care so that the 
machine front and rear are balanced (in posi- 
tion, etc.) when setting the front fork. 
1. Use of soft spring 

Generally a soft spring gives a soft riding 
feeling. Rebound damping tends to 
become stronger and the front fork may 
sink deeply over a series of gaps. 
To set a soft spring: 

• Change the rebound damping. 
Turn out one or two clicks. 

• Change the compression damping. 
Turn in one or two clicks. 



7-13 



SETTING 




80 kg 
(176 1b) 
70 kg 
(154 1b) 
60 kg 
(132 1b) 
50 kg 
(110 1b) 
40 kg 
(88 lb) 





m 






- 








<D 












— 




© 
















- 


© 











2. Use of stiff spring 

Generally a stiff spring gives a stiff riding 
feeling. Rebound damping tends to 
become weaker, resulting in lack of a 
sense of contact with the road surface or 
in a vibrating handlebar. 
To set a stiff spring: 

• Change the rebound damping. 
Turn in one or two clicks. 

• Change the compression damping. 
Turn out one or two clicks. 

S Coverage of spring by weight 

\s\ Rider weight 

©Soft 

© Standard 

© Stiff 



7-14 



SETTING 





EC72P000 



Front fork setting parts 

• Adjustment washer © 



TYPE (thickness) 


PART NUMBER 


T = 2.3 mm (0.09 in) 


4SS-23364-L0 



• Front fork spring (2) 
[Equal pitch spring] 



TYPE 


SPRING 
RATE 


SPRING 
PART NUMBER 


I.D. 
MARK 
(slits) 


SOFT 
STIFF 


0.380 
0.390 
0.400 
0.410 
0.420 
0.430 
0.440 


4SS-23141-10 
4SS-23141-20 
4SS-23141-30 
4SS-23141-40 
4SS-23141-50 
4SS-23141-60 
4SS-23141-70 


l-l 
Ml 
Mil 

I 

II 
III 
INI 


STD 


0.460 


5GR-23141-L0 


- 



[Unequal pitch spring] 




TYPE 


SPRING 

RATE 

(approx.) 


SPRING 
PART NUMBER 


I.D. 
MARK 
(slits) 


SOFT 
STIFF 


0.400 
0.410 
0.420 
0.430 
0.440 


5ET-23141-20 
5ET-23141-00 
5ET-23141-30 
5ET-23141-10 
5ET-23141-40 


V 

V-l 

V-ll 

V-lll 

V-llll 



NOTE: 

• The unequal pitch spring is softer in initial 
characteristic than the equal pitch spring and 
is difficult to bottom out under full compres- 
sion. 

• The I.D. mark (slits) ® is proved on the end 
of the spring. 



7-15 



SETTING 




EC72B000 

Rear suspension setting 

The rear suspension setting should be made 
depending on the rider's feeling of an actual 
run and the circuit conditions. 
The rear suspension setting includes the fol- 
lowing two factors: 

1 . Setting of spring preload 

• Change the set length of the spring. 

• Change the spring. 

2. Setting of damping force 

• Change the rebound damping. 

• Change the compression damping. 




EC72C001 

Choosing set length 

1. Place a stand or block under the engine 
to put the rear wheel above the floor, and 
measure the length (a) between the rear 
wheel axle center and the rear fender 
holding bolt. 



2. 



Remove the stand or block from the 
engine and with a rider astride the seat, 
measure the sunken length © between 
the rear wheel axle center and the rear 
fender holding bolt. 



Loosen the locknut © and make adjust- 
ment by turning the spring adjuster ® to 
achieve the standard figure from the sub- 
traction of the length (b) from the length 

(a). 




Standard figure: 
90-100 mm (3.5 ~ 3.9 in) 



7-16 



SETTING 




NOTE: 

• If the machine is new and after it is broken in, 
the same set length of the spring may 
change because of the initial fatigue, etc. of 
the spring. Therefore, be sure to make re- 
evaluation. 

• If the standard figure cannot be achieved by 
adjusting the spring adjuster and changing 
the spring set length, replace the spring with 
an optional one and make re-adjustment. 



EC72G001 

Setting of spring after replacement 

After replacement, be sure to adjust the spring 
to the set length [sunken length 90 ~ 100 mm 
(3.5 ~ 3.9 in)] and set it. 

1. Use of soft spring 

• Set the soft spring for less rebound 
damping to compensate for its less 
spring load. Run with the rebound 
damping adjuster one or two clicks on 
the softer side and readjust it to suit 
your preference. 

2. Use of stiff spring 

• Set the soft spring for more rebound 
damping to compensate for its greater 
spring load. Run with the rebound 
damping adjuster one or two clicks on 
the stiffer side and readjust it to suit 
your preference. 

* Adjusting the rebound damping will be 
followed more or less by a change in the 
compression damping. For correction, 
turn the low compression damping 
adjuster on the softer side. 



7-17 



SETTING 





1^ 

When using a rear cushion other than cur- 
rently installed, use the one whose overall 
length ® does not exceed the standard as 
it may result in faulty performance. Never 
use one whose overall length is greater 
than standard. 



30 |<g 











(176 1b) - 
70 kg — 
(154 lb) 






(D 








[g 60 kg _ 
(132 lb) 






© 






50 kg 

(110 1b) 
40 kg 








© 








(88 lb) 










Length ® of standard shock: 
490.5 mm (19.31 in) 



\E Coverage of spring by weight 

M Rider weight 

© Soft 

© Standard 

© Stiff 



7-18 



SETTING 





EC72Q000 



Rear shock absorber setting parts 

• Rear shock spring © 
[Equal pitch spring] 



TYPE 


SPRING 
RATE 


SPRING 
PART NUMBER 


I.D. 

COLOR/ 

POINT 


SPRING 

FREE 
LENGTH 


SOFT 


4.3 
4.5 
4.7 
4.9 
5.1 


5UN-22212-00 
5UN-22212-10 
5UN-22212-20 
5UN-22212-30 
5UN-22212-40 


Brown/1 
Green/1 

Red/1 
Black/1 

Blue/1 


260 
260 
260 
260 
260 


STD 


5.3 


5UN-22212-50 


Yellow/1 


260 


STIFF 


5.5 
5.7 


5UN-22212-60 
5UN-22212-70 


Pink/1 
White/1 


260 
260 



[Unequal pitch spring] 



TYPE 


SPRING 

RATE 
(approx.) 


SPRING 
PART NUMBER 


I.D. 

COLOR/ 

POINT 


SPRING 

FREE 
LENGTH 


SOFT 


4.5 
4.7 
4.9 
5.1 


5UN-22212-A0 
5UN-22212-B0 
5UN-22212-C0 
5UN-22212-D0 


Green/2 
Red/2 

Black/2 
Blue/2 


275 
275 
275 
275 


*STD 


5.3 


5UN-22212-E0 


Yellow/2 


275 


STIFF 


5.5 
5.7 


5UN-22212-F0 
5UN-22212-G0 


Pink/2 
White/2 


275 
275 



*For EUROPE 
NOTE: 



• The unequal pitch spring is softer in initial 
characteristic than the equal pitch spring and 
is difficult to bottom out under full compres- 
sion. 

• The I.D. color ® is marked at the end of the 
spring. 




Extent of adjustment (spring length) 



SPRING FREE 
LENGTH 


EXTENT OF 
ADJUSTMENT © 


260 mm (10.24 in) 


240.5 ~ 258.5 mm 
(9.47 -10.18 in) 


275 mm (10.83 in) 


255.5 ~ 273.5 mm 
(10.06 -10.77 in) 



7-19 



SETTING 




EC72H002 

Suspension setting 

• Front fork 

NOTE: 



• If any of the following symptoms is experienced with the standard position as the base, make 
resetting by reference to the adjustment procedure given in the same chart. 

• Before any change, set the rear shock absorber sunken length to the standard figure 90 ~ 
100 mm (3.5 ~ 3.9 in). 



Symptom 


Section 


Check 


Adjust 


Jump 


Large 
gap 


Medium 
gap 


Small 
gap 


Stiff over entire range 


O 


O 


O 




Compression damping 

Oil level (oil amount) 
Spring 


Turn adjuster counterclockwise (about 2 clicks) to 
decrease damping. 

Decrease oil level by about 5-10 mm (0.2 ~ 0.4 in). 
Replace with soft spring. 


Unsmooth movement 
over entire range 


O 


o 


O 


O 


Outer tube 

Inner tube 

Under bracket tightening 

torque 


Check for any bends, dents, and other noticeable 
scars, etc. If any, replace affected parts. 
Retighten to specified torque. 


Poor initial 
movement 








o 


Rebound damping 
Oil seal 


Turn adjuster counterclockwise (about 2 clicks) to 

decrease damping. 

Apply grease in oil seal wall. 


Soft over entire range, 
bottoming out 


O 


o 






Compression damping 

Oil level (oil amount) 
Spring 


Turn adjuster clockwise (about 2 clicks) to increase 

damping. 

Increase oil level by about 5-10 mm (0.2 ~ 0.4 in). 

Replace with stiff spring. 


Stiff toward stroke end 


O 








Oil level (oil amount) 


Decrease oil level by about 5 mm (0.2 in). 


Soft toward stroke end, 
bottoming out 


O 








Oil level (oil amount) 


Increase oil level by about 5 mm (0.2 in). 


Stiff initial movement 


O 


o 


O 


o 


Compression damping 


Turn adjuster counterclockwise (about 2 clicks) to 
decrease damping. 


Low front, tending to 
lower front posture 






O 


o 


Compression damping 
Rebound damping 
Balance with rear end 
Oil level (oil amount) 


Turn adjuster clockwise (about 2 clicks) to increase 

damping. 

Turn adjuster counterclockwise (about 2 clicks) to 

decrease damping. 

Set sunken length for 95-100 mm (3.7 - 3.9 in) when 

one passenger is astride seat (lower rear posture). 

Increase oil level by about 5 mm (0.2 in). 


"Obtrusive" front, tend- 
ing to upper front pos- 
ture 






O 


o 


Compression damping 

Balance with rear end 

Spring 

Oil lever (oil amount) 


Turn adjuster counterclockwise (about 2 clicks) to 

decrease damping. 

Set sunken length for 90 - 95 mm (3.5 - 3.7 in) when 

one passenger is astride seat (upper rear posture). 

Replace with soft spring. 

Decrease oil level by about 5-10 mm (0.2 - 0.4 in). 



7-20 



SETTING 




• Rear shock absorber 
NOTE: 



• If any of the following symptoms is experienced with the standard position as the base, make 
resetting by reference to the adjustment procedure given in the same chart. 

• Adjust the rebound damping in 2-click increments or decrements. 

• Adjust the low compression damping in 1 -click increments or decrements. 

• Adjust the high compression damping in 1/6 turn increments or decrements. 



Symptom 


Section 


Check 


Adjust 


Jump 


Large 
gap 


Medium 
gap 


Small 
gap 


Stiff, tending to sink 






O 


O 


Rebound damping 
Spring set length 


Turn adjuster counterclockwise (about 2 clicks) to 
decrease damping. 

Set sunken length for 90-100 mm (3.5 ~ 3.9 in) when 
one passenger is astride seat. 


Spongy and unstable 






O 


o 


Rebound damping 

Low compression damping 

Spring 


Turn adjuster clockwise (about 2 clicks) to increase 

damping. 

Turn adjuster clockwise (about 1 click) to increase 

damping. 

Replace with stiff spring. 


Heavy and dragging 






O 


o 


Rebound damping 
Spring 


Turn adjuster counterclockwise (about 2 clicks) to 
decrease damping. 
Replace with soft spring. 


Poor road gripping 








o 


Rebound damping 

Low compression damping 

High compression damp- 
ing 
Spring set length 

Spring 


Turn adjuster counterclockwise (about 2 clicks) to 

decrease damping. 

Turn adjuster clockwise (about 1 clicks) to increase 

damping. 

Turn adjuster clockwise (about 1/6 clicks) to increase 

damping. 

Set sunken length for 90-100 mm (3.5 ~ 3.9 in) when 

one passenger is astride seat. 

Replace with soft spring. 


Bottoming out 


O 


O 






High compression damp- 
ing 
Spring set length 

Spring 


Turn adjuster clockwise (about 1/6 turn) to increase 

damping. 

Set sunken length for 90-100 mm (3.5 - 3.9 in) when 

one passenger in astride seat. 

Replace with stiff spring. 


Bouncing 


O 


o 






Rebound damping 
Spring 


Turn adjuster clockwise (about 2 clicks) to increase 

damping. 

Replace with soft spring. 


Stiff travel 


O 


o 






High compression damp- 
ing 
Spring set length 

Spring 


Turn adjuster counterclockwise (about 1/6 turn) to 

decrease damping. 

Set sunken length for 95-100 mm (3.7 - 3.9 in) when 

one passenger is astride seat. 

Replace with soft spring. 



7-21 



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PRINTED IN JAPAN 
2002.06-2.9x1